CN113043752B

CN113043752B - Printing system assembly and method

Info

Publication number: CN113043752B
Application number: CN202110159113.6A
Authority: CN
Inventors: R.劳兰斯; A.S-K.柯; J.莫克; E.弗伦斯基; A.赫鲁斯塔列夫; K.马蒂亚; S.阿尔德森
Original assignee: Kateeva Inc
Current assignee: Kateeva Inc
Priority date: 2014-06-17
Filing date: 2015-06-12
Publication date: 2022-10-25
Anticipated expiration: 2035-06-12
Also published as: KR102528105B1; KR102647049B1; TWI637544B; CN106457304B; JP2022008686A; US10414181B2; CN115946453A; US9505245B2; US11626311B2; US9884501B2; KR20240036141A; US20150360462A1; WO2015195493A8; TW201843863A; JP2020093259A; KR102327982B1; US20180264862A1; TW201616704A; JP6958942B2; US20170129265A1

Abstract

The present teachings disclose various embodiments of a printing system for printing a substrate, wherein the printing system may be housed in a gas enclosure, wherein the environment within the enclosure may be maintained as a controlled printing environment. The controlled environment of the present teachings may include: control of the type of gaseous environment within the gas enclosure, control of the size and level of particulate matter within the enclosure, control of temperature within the enclosure, and control of lighting. Various embodiments of a printing system of the present teachings may include a Y-axis motion system and a Z-axis moving plate configured to substantially reduce excessive thermal loading within the gas enclosure by, for example, eliminating or substantially minimizing the use of conventional motors.

Description

Printing system assembly and method

Technical Field

The present teachings relate to various embodiments of a printing system that may be maintained in a gas enclosure system defining an interior having an inert, substantially low-particle environment.

Cross reference to related applications

This application claims the benefit of: (1) U.S. provisional patent application No. 62/013,433, filed 6/17/2014; (2) U.S. provisional patent application No. 62/021,390, filed 7/2014; (3) U.S. provisional patent application No. 62/037,494, filed on 8/14/2014; (4) U.S. provisional patent application No. 62/013,440, filed 6/17 2014; (5) U.S. provisional patent application No. 62/021,563, filed 7/2014; (6) U.S. provisional patent application No. 62/044,165, filed on 8/29 2014; (7) U.S. provisional patent application No. 62/092,721, filed on 16/12/2014; each application is incorporated by reference herein in its entirety.

SUMMARY

Interest in the potential of Organic Light Emitting Diode (OLED) display technology has been driven by OLED display technology attributes including demonstration of display panels with highly saturated colors, high contrast, ultra-thin, fast response, and power savings. In addition, various substrate materials (including flexible polymer materials) can be used in the fabrication of OLED display technologies. While demonstrations of displays for small screen applications (primarily for mobile phones) have been used to emphasize the potential of this technology, challenges remain in scaling high volume manufacturing at high throughput in a range of substrate formats.

For format scaling, the Gen 5.5 substrate has dimensions of about 130cm x 150cm, and can produce about 8 26 "flat panel displays. In contrast, larger format substrates may include using Gen 7.5 and Gen 8.5 mother glass substrate sizes. Gen 7.5 mother glasses have dimensions of about 195cm x 225cm and can be cut into 8 42 "or 6 47" flat panel displays per substrate. The mother glass for Gen 8.5 is approximately 220cm x 250cm and can be cut into 6 55 "or 8 46" flat panel displays per substrate. One indication of the challenge in scaling OLED display manufacturing into larger formats is: high volume manufacturing of OLED displays at high throughput on substrates larger than Gen 5.5 substrates has proven to be very challenging.

In principle, OLED devices can be manufactured by printing various organic thin films, as well as other materials, on a substrate using an OLED printing system. Such organic materials may be susceptible to damage from oxidation and other chemical processes. Housing OLED printing systems in a manner that can scale to various substrate sizes and can be performed in an inert, substantially low-particle printing environment can present various engineering challenges. Manufacturing tools for high throughput large format substrate printing (e.g., such as printing of Gen 7.5 and Gen 8.5 substrates) require very large facilities. Thus, maintaining large facilities in an inert environment, requiring gas purging to remove reactive atmospheric species (such as water vapor and oxygen and organic solvent vapors), and maintaining a substantially low particle printing environment have proven extremely challenging.

Also, there remains a challenge in manufacturing OLED displays in a range of substrate formats with high volume scaling. Accordingly, various embodiments present a need for various embodiments of the gas enclosure system of the present teachings that can house an OLED printing system in an inert, substantially low-particle environment, and that can be easily scaled to provide for the fabrication of OLED panels on a variety of substrate sizes and substrate materials. In addition, various gas enclosure systems of the present teachings can provide rapid access to the OLED printing system from the outside during processing and provide access to the inside for maintenance with minimal downtime.

Drawings

A better understanding of the features and advantages of the present disclosure will be obtained by reference to the accompanying drawings, which are intended to illustrate, but not to limit, the present teachings. In the drawings, which are not necessarily drawn to scale, like numerals may describe similar parts throughout the different views. Like numerals having different letter suffixes may represent different instances of similar components.

FIG. 1A is a front perspective view of a gas enclosure assembly according to various embodiments of the present teachings. FIG. 1B depicts an exploded view of various embodiments of a gas enclosure assembly as depicted in FIG. 1A. FIG. 1C depicts an expanded isometric perspective view of the printing system depicted in FIG. 1B. FIG. 1D is an exploded perspective view of an auxiliary enclosure of a gas enclosure system according to various embodiments of the present teachings.

FIG. 2A is a front perspective view of a gas enclosure assembly according to various embodiments of the present teachings. FIG. 2B is a partially exploded perspective view of an auxiliary enclosure of a gas enclosure system according to various embodiments of the present teachings. FIG. 2C is a partially exploded top perspective view of an auxiliary enclosure of a gas enclosure system according to various embodiments of the present teachings.

FIG. 3 is an expanded isometric view of a printing system according to the present teachings, showing a Y-axis motion system.

Figure 4A is a top view of a Y-axis motion system in accordance with various embodiments of systems and methods according to the present teachings. Fig. 4B is an expanded partial top view of fig. 4A.

Figure 5A is an isometric view of a Y-axis motion system according to various embodiments of systems and methods of the present teachings. Fig. 5B is a long sectional view of fig. 5A.

Fig. 6 is a side view of a side frame of a carriage assembly having a gripper motion control assembly mounted thereon.

Figure 7A is an isometric view of a voice coil assembly according to various embodiments of systems and methods of the present teachings. Fig. 7B is a side view of the voice coil assembly.

FIG. 8 is a top view of a Y-axis motion system indicating two cross-sectional views of various embodiments of systems and methods according to the present teachings.

Fig. 9 is a cross-sectional view of the voice coil assembly as indicated in fig. 8.

Fig. 10 is a cross-sectional view of the center pivot assembly as indicated in fig. 8.

FIG. 11 is a schematic diagram of a closed loop control circuit providing pneumatic balancing to a Z-axis motor, in accordance with various embodiments of the systems and methods of the present teachings.

Figure 12A is an isometric perspective view of a Z-axis moving plate having airlift elements, and figure 12B is a front perspective view of a Z-axis moving plate having airlift elements, according to various embodiments of the present teachings.

FIG. 13 is a schematic diagram of a closed printing system that can utilize various embodiments of an ink delivery system according to the present teachings.

FIG. 14 is a schematic view of a bulk ink delivery system according to various embodiments of the present teachings.

FIG. 15 is a schematic view of a bulk ink delivery system according to various embodiments of the present teachings.

FIG. 16 is a schematic diagram of a partial ink delivery system for a closed printing system, according to various embodiments of the present teachings.

FIG. 17 is a schematic diagram of a partial ink delivery system in flow communication with a printhead ink delivery system for a closed printing system according to various embodiments of the present teachings.

FIG. 18A is a bottom perspective view of a printhead assembly mounted on an X-axis bridge. Fig. 18B is an expanded view of fig. 18A.

FIG. 19A is a front top perspective view of a printhead device, and FIG. 19B is a front bottom perspective view of a printhead device according to various embodiments of the present teachings. FIG. 19C is a front top perspective view of a mounting plate for a printhead device, and FIG. 19D is a front bottom perspective view of a printhead device mounted in a mounting assembly according to various embodiments of the present teachings.

FIG. 20 is a schematic diagram of various embodiments of a gas enclosure assembly and associated system components of the present teachings.

Fig. 21A and 21B are schematic diagrams of various embodiments of enclosed printing systems and components for integrating and controlling a gas source (such as may be used to establish a controlled gas environment in a gas enclosure), where the various embodiments may include a pressurized gas supply for use with a floating station.

Fig. 22A-22C are schematic diagrams of various embodiments of enclosed printing systems and components for integrating and controlling a gas source (such as may be used to establish a controlled gas environment in a gas enclosure), where the various embodiments may include a blower circuit to provide, for example, pressurized gas for use with a floating stage and a vacuum source.

Detailed Description

The present teachings disclose various embodiments of a printing system for printing a substrate, wherein the printing system may be housed in a gas enclosure, wherein the environment within the enclosure may be maintained as a controlled printing environment. The controlled environment of the present teachings may include: control over the type of gaseous environment within the gas enclosure, control over the size and level of particulate matter within the enclosure, control over the temperature within the enclosure, and control over the lighting. Various embodiments of a printing system of the present teachings may include a Y-axis motion system and a Z-axis moving plate assembly configured to substantially reduce excessive thermal loads within a gas enclosure, for example, by eliminating or substantially minimizing the use of conventional motors. Additionally, various embodiments of the Y-axis motion system of the present teachings may include a gripper motion control assembly configured to provide high precision Y-axis motion system of dynamic orientation rotation of the substrate about the theta-Z (θ -Z) axis during Y-axis travel to maintain substrate orientation parallel to the travel axis.

Various embodiments of the gas enclosure assembly may be hermetically constructed and integrated with various components that provide gas circulation and filtration systems, particle control systems, gas purification systems, and thermal regulation systems, among others, to form various embodiments of gas enclosure systems that may maintain a substantially low-particle inert gas environment for processes requiring such an environment. Various embodiments of the gas enclosure may have a printing system enclosure and an auxiliary enclosure constructed as part of the gas enclosure assembly that may be sealingly separated from the gas enclosure printing system enclosure. Various embodiments of a printing system of the present teachings may have a printhead management system enclosed in a secondary enclosure. Embodiments of a printhead management system of the present teachings can include various devices and apparatus for maintenance and calibration of printheads; the various devices and equipment are each mounted on a motion system platform for fine positioning of the various devices and equipment relative to the printhead.

The printing system shown in the expanded view in fig. 1C (such as printing system 2000 of fig. 1B) may be comprised of several devices and apparatuses that allow for the reliable placement of ink drops onto specific locations on a substrate. Printing requires relative motion between the printhead assembly and the substrate. This can be done using a motion system (usually a gantry or split axis XYZ system). The printhead assembly may move on a stationary substrate (gantry), or both the printhead and the substrate may move in a split-axis configuration. In another embodiment, the printhead assembly can be substantially stationary; for example, in the X and Y axes, the substrate may be moved relative to the printhead in the X and Y axes with Z axis motion provided by the substrate support apparatus or by a Z axis motion system associated with the printhead assembly. As the printhead moves relative to the substrate, ink drops are ejected at the correct time to be deposited in the desired location on the substrate. A substrate loading and unloading system may be used to insert and remove substrates from the printer. Depending on the printer configuration, this may be done using a mechanical conveyor, a substrate floatation table with a conveyor assembly, or a substrate transfer robot with an end effector. For various embodiments of the systems and methods of the present teachings, the Y-axis motion system may be based on an air bearing clamp system.

For a clearer view of the substrate sizes that can be used for the manufacture of various OLED concepts, several generations of mother glass substrate sizes have undergone evolution from flat panel displays manufactured by printing other than OLEDs, starting around the beginning of the 90's of the 20 th century. The first generation mother glass substrate (designated Gen 1) was approximately 30cm x 40cm, and therefore, 15 "panels could be produced. In the mid 90's of the 20 th century, the prior art for producing flat panel displays has evolved to Gen 3.5 mother glass substrate sizes having dimensions of about 60cm x 72cm. In contrast, gen 5.5 substrates have dimensions of about 130cm x 150cm.

With each generation of development, mother glass sizes of Gen 7.5 and Gen 8.5 were produced for processes other than OLED printing manufacturing. Gen 7.5 mother glass has dimensions of about 195cm x 225cm and can be cut into 8 42 "or 6 47" plates per substrate. The mother glass for Gen 8.5 is approximately 220cm x 250cm and can be cut into 6 55 "or 8 46" flat sheets per substrate. Expectations for qualities such as truer color, higher contrast, thinness, flexibility, transparency, and energy efficiency of OLED flat panel displays have been achieved, while OLED fabrication is effectively limited to G3.5 and smaller. Currently, OLED printing is considered the best fabrication technique to break this limitation and enable OLED panel fabrication not only for Gen 3.5 and smaller mother glass sizes, but also for the largest mother glass sizes, such as Gen 5.5, gen 7.5, and Gen 8.5. One of the features of OLED panel display technology includes the possibility of using various substrate materials, such as, but not limited to, various glass substrate materials and various polymer substrate materials. In this regard, the size of the term statement arising from the use of glass-based substrates may be applied to substrates of any material suitable for use in OLED printing.

In principle, a manufacturing tool that may allow printing of various substrate sizes, including large format substrate sizes, may require a very large facility for accommodating such an OLED manufacturing tool. Therefore, maintaining the entire large facility in an inert environment presents engineering challenges, such as the continuous purging of large volumes of inert gas. Various embodiments of the gas enclosure system may have a circulation and filtration system inside the gas enclosure assembly in combination with a gas purification system outside the gas enclosure that, in conjunction with the gas purification system, may provide continuous circulation of substantially low-particle inert gas having substantially low levels of reactive species throughout the gas enclosure system. The inert gas may be any gas that does not undergo a chemical reaction under a defined set of conditions in accordance with the present teachings. Some common non-limiting examples of inert gases may include nitrogen, any noble gas, and any combination thereof. In addition, providing a large facility that is substantially airtight to prevent contamination by various reactive atmospheric gases (such as water vapor and oxygen, and organic solvent vapors generated from various printing processes) poses engineering challenges. In accordance with the present teachings, an OLED printing facility maintains the levels of each of various reactive species (including various reactive atmospheric gases, such as water vapor and oxygen, and organic solvent vapor) at 100ppm or less, for example, 10ppm or less, 1.0ppm or less, or 0.1ppm or less.

The need to print OLED panels in a facility where the level of each of the reactive species should be maintained at a target low level may be shown in reviewing the information summarized in table 1. The data summarized on table 1 results from testing individual samples fabricated in a large pixel spin-on device format that included organic thin film compositions for each of the red, green, and blue colors. Such specimens are substantially easier to manufacture and test for the purpose of rapid evaluation of various formulations and processes. Although the coupon test should not be confused with the life test of the printed panel, it may indicate the effect of various formulations and processes on life. The results shown in the following table represent variations in process steps in the fabrication of samples where only the spin-on environment varied for samples fabricated in a nitrogen environment with less than 1ppm of reactive species compared to samples similarly fabricated in air rather than a nitrogen environment.

By examining the data in table 1 for samples made under different processing environments, particularly in the case of red and blue, it is evident that printing in an environment effective to reduce exposure of the organic thin film composition to reactive species can have a substantial effect on the stability, and thus lifetime, of the various ELs. Lifetime specifications are particularly important for OLED panel technology as this is directly related to display product lifetime; product specifications for all panel technologies, which have been challenges encountered with OLED panel technologies. To provide a panel that meets the requisite lifetime specifications, various embodiments of the gas enclosure systems of the present teachings can be utilized to maintain the level of each of the reactive species (such as water vapor, oxygen, and organic solvent vapor) at 100ppm or less, for example, 10ppm or less, 1.0ppm or less, or 0.1ppm or less.

Table 1: the effect of the inert gas treatment on the lifetime of the OLED panel.

In addition to providing an inert environment, maintaining a substantially low particle environment for OLED printing is important because even very small particles can cause visible defects on the OLED panel. Particle control in gas containment systems can present significant challenges not presented by processes that can be performed in, for example, open air, high flow laminar flow filter hoods, atmospheric conditions. For example, a manufacturing facility may require a substantial length of various service bundles that may be operably connected from various systems and components to provide the optical, electrical, mechanical, and fluidic connections required for operation of, for example, but not limited to, a printing system. Such service beams used for operation of the printing system and located close to the substrate positioned for printing may be a continuous source of particulate matter. Additionally, the component for the printing system (such as a fan or linear motion system using friction bearings) may be a particle generating component. Various embodiments of gas circulation and filtration systems of the present teachings may be used in conjunction with particulate control components to contain and exclude particulate matter. In addition, by using various essentially low particle generating pneumatically operated components (such as, but not limited to, substrate floatation tables, air bearings, and pneumatically operated robots, etc.), a low particle environment for various embodiments of the gas enclosure system can be maintained.

With respect to maintaining a substantially low-particle environment, various embodiments of the gas circulation and filtration system may be designed to provide a low-particle inert gas environment for airborne particulates that meets the standards specified by the international organization for standards (ISO) 14644-1, 1999 clearance and associated controlled environments-Part 1. However, controlling airborne particulate matter alone is not sufficient to provide a low particulate environment proximate to the substrate during, for example, but not limited to, a printing process, as particles generated proximate to the substrate during such a process may accumulate on the substrate surface before they are swept away by the gas circulation and filtration system.

Thus, in conjunction with a gas circulation and filtration system, various embodiments of gas enclosure systems of the present teachings can have a particle control system that can include components that can provide access to a low particle region of a substrate during processing in a printing step. Particle control systems for various embodiments of gas enclosure systems of the present teachings may include a gas circulation and filtration system, a low particle generating X-axis linear bearing system for moving a printhead assembly relative to a substrate, a service bundle housing exhaust system, and a printhead assembly exhaust system. For example, the gas enclosure system may have a gas circulation and filtration system inside the gas enclosure assembly.

Various embodiments of systems and methods of the present teachings can maintain a substantially low-particle environment that provides an average on-substrate distribution of particles of a particular size range of interest that does not exceed a deposition rate specification on a substrate. The on-substrate deposition rate specification may be set to between about 0.1 μm and greater and about 10 μm and greater for each of the particle size ranges of interest. In various embodiments of the systems and methods of the present teachings, the particle deposition rate specification on the substrate can be expressed as: a limit on the number of particles deposited per square meter of substrate per minute for each of the target particle size ranges.

Various embodiments of particle deposition rate specifications on substrates can be easily converted from the limit of the number of particles deposited per square meter of substrate per minute to: a limit on the number of particles deposited per substrate per minute for each of the target particle size ranges. Such a conversion can be easily made by a known relationship between the substrate (e.g., of a particular generation size of substrate) and the corresponding area of that generation of substrate. For example, table 2 below summarizes the aspect ratios and areas of some known generation size substrates. It should be understood that slight variations in aspect ratio, and thus in size, may be seen from different manufacturers. However, regardless of such variations, any of the various generation-sized substrates may acquire conversion factors for the particular generation-sized substrate and the area calculated in square meters.

Surrogate ID	X(mm)	Y(mm)	Area (m) ² )
				Gen 3.0	550	650	0.36
Gen 3.5	610	720	0.44
				Gen 3.5	620	750	0.47
Gen 4	680	880	0.60
				Gen 4	730	920	0.67
Gen 5	1100	1250	1.38
				Gen 5	1100	1300	1.43
Gen 5.5	1300	1500	1.95
				Gen 6	1500	1850	2.78
Gen 7.5	1950	2250	4.39
				Gen 8	2160	2400	5.18
Gen 8	2160	2460	5.31
				Gen 8.5	2200	2500	5.50
Gen 9	2400	2800	6.72
				Gen 10	2850	3050	8.69

Table 2: the correlation between area and substrate size.

In addition, the on-substrate particle deposition rate specification, expressed as a limit on the number of particles deposited per square meter of substrate per minute, can be readily converted to any of a variety of unit time expressions. It will be readily appreciated that the particle deposition rate specification on a substrate normalized to minutes can be readily converted to any other temporal expression by a known relationship of time (e.g., without limitation, such as seconds, hours, days, etc.). In addition, time units specifically related to the process may be used. For example, a print cycle may be associated with a unit of time. For various embodiments of a gas enclosure system according to the present teachings, a print cycle may be a time period in which a substrate is moved into the gas enclosure system for printing and then removed from the gas enclosure system after printing is complete. For various embodiments of a gas enclosure system according to the present teachings, a print cycle may be a period of time from the beginning of alignment of a substrate relative to a printhead assembly to the transfer of the last drop of ejected ink onto the substrate. In the field of process technology, the overall average cycle time or TACT may be a representation of the time unit for a particular process cycle. According to various embodiments of systems and methods of the present teachings, TACT for a print cycle can be about 30 seconds. For various embodiments of systems and methods of the present teachings, TACT for a print cycle may be about 60 seconds. In various embodiments of the systems and methods of the present teachings, TACT for a print cycle may be about 90 seconds. For various embodiments of systems and methods of the present teachings, TACT for a print cycle may be about 120 seconds. In various embodiments of the systems and methods of the present teachings, TACT for a print cycle may be about 300 seconds.

With respect to airborne particulate matter and particle deposition within the system, a number of variables can affect: a general model of a value that can be adequately calculated for any particular manufacturing system, e.g., the particle shedding rate on a surface (such as a substrate) is developed. Variables such as size of particles, distribution of particles of a particular size; the surface area of the substrate and the exposure time of the substrate within the system may vary depending on the various manufacturing systems. For example, the size of the particles and the distribution of particles of a particular size may be substantially affected by the source and location of the particle generating components in the various manufacturing systems. Calculations based on various embodiments of the gas enclosure system of the present teachings show that: without the various particle control systems of the present teachings, the deposition on the substrate of particulate matter per print cycle per square meter of substrate may be between more than about 1 million particles to more than about 10 million particles for particles in the size range of 0.1 μm and greater. This calculation shows that: without the various particle control systems of the present teachings, the deposition on the substrate of particulate matter per print cycle per square meter of substrate may be between more than about 1000 particles to about more than about 10000 particles per square meter of substrate for particles in the size range of about 2 μm and greater.

Various embodiments of a low-particle gas enclosure system of the present teachings can maintain a low-particle environment that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 100 particles per square meter of substrate per minute for particles having a size greater than or equal to 10 μm. Various embodiments of a low-particle gas enclosure system of the present teachings can maintain a low-particle environment that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 100 particles per square meter of substrate per minute for particles having a size greater than or equal to 5 μm. In various embodiments of the gas enclosure system of the present teachings, a low-particle environment can be maintained that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 100 particles per square meter of substrate per minute for particles having a size greater than or equal to 2 μm. In various embodiments of the gas enclosure system of the present teachings, a low-particle environment can be maintained that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 100 particles per square meter of substrate per minute for particles having a size greater than or equal to 1 μm. Various embodiments of a low-particle gas enclosure system of the present teachings can maintain a low-particle environment that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 1000 particles per square meter of substrate per minute for particles having a size greater than or equal to 0.5 μm. Various embodiments of a gas enclosure system according to the present teachings may maintain a low particle environment that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification of less than or equal to about 1000 particles per square meter of substrate per minute for particles having a size greater than or equal to 0.3 μm. Various embodiments of the low-particle gas enclosure system of the present teachings can maintain a low-particle environment that provides an average on-substrate particle distribution that meets an on-substrate deposition rate specification for particles having a size greater than or equal to 0.1 μm, and less than or equal to about 1000 particles per square meter of substrate per minute.

It is contemplated that a variety of ink formulations may be printed within the inert, substantially low-particle environment of various embodiments of the gas enclosure system of the present teachings. During the manufacture of an OLED display, OLED pixels may be formed to include an OLED thin film stack that may emit light of a particular peak wavelength upon application of a voltage. The OLED thin film stack structure between the anode and the cathode may include a Hole Injection Layer (HIL), a Hole Transport Layer (HTL), an Emission Layer (EL), an Electron Transport Layer (ETL), and an Electron Injection Layer (EIL). In some embodiments of the OLED thin film stack structure, an Electron Transport Layer (ETL) may be combined with an Electron Injection Layer (EIL) to form an ETL/EIL layer. In accordance with the present teachings, various ink formulations for the EL for various color pixel EL films of an OLED film stack can be printed using, for example, ink jet printing. Additionally, for example, but not limited to, the HIL, HTL, EML, and ETL/EIL layers may have ink formulations that can be printed using inkjet printing.

It is further contemplated that the organic encapsulation layer may be printed on the substrate print. It is contemplated that the organic packaging layer may be printed using inkjet printing, as inkjet printing may provide several advantages. First, a series of vacuum processing operations can be eliminated, as such inkjet-based manufacturing can be performed at atmospheric pressure. In addition, during the inkjet printing process, the organic encapsulation layer can be localized to cover portions of the OLED substrate above and proximate to the active area to effectively encapsulate the active area, including the side edges of the active area. The targeted patterning using inkjet printing results in: eliminating material waste and eliminating the additional processing typically required to achieve patterning of organic layers. The packaging ink may include a polymer (including, for example and without limitation, acrylates, methacrylates, urethanes, or other materials, as well as copolymers and mixtures thereof) that may be cured by using a thermal treatment (e.g., baking), UV exposure, and combinations thereof. As used herein, polymers and copolymers may include any form of polymer component that can be formulated into an ink and cured on a substrate to form an organic packaging layer. Such polymer components may include polymers, and copolymers, as well as their precursors, such as, but not limited to, monomers, oligomers, and resins.

Various embodiments of the gas enclosure assembly may have various frame members configured to provide a profile for the gas enclosure assembly. Various embodiments of the gas enclosure assembly of the present teachings can accommodate an OLED printing system while optimizing the workspace to minimize inert gas volumes and allowing external access to the OLED printing system during processing. In this regard, the various gas enclosure assemblies of the present teachings can have a contoured topology and volume. As will be discussed in more detail later herein, various embodiments of the gas enclosure may be contoured around a printing system pedestal on which the substrate support apparatus may be mounted. Further, the gas enclosure may be contoured around a bridge structure of the printing system for X-axis movement of the carriage assembly. As a non-limiting example, various embodiments of contoured gas enclosures in accordance with the present teachings may have a width of about 6m for accommodating various embodiments of printing systems capable of printing substrate sizes from Gen 3.5 to Gen 10 ³ To about 95m ³ The gas enclosure between. By way of another non-limiting example, various embodiments of contoured gas enclosures in accordance with the present teachings may have a thickness of approximately 15m for housing various embodiments of printing systems capable of printing, for example, gen 5.5 to Gen 8.5 substrate sizes ³ To about 30m ³ The gas in between encloses a volume. Such an embodiment of the contoured gas envelope may save between about 30% and about 70% in volume as compared to a non-contoured envelope having non-contoured dimensions for width, length, and height.

FIG. 1A depicts a perspective view of a gas enclosure assembly 1000 of various embodiments of gas enclosure assemblies according to the present teachings. Gas enclosure assembly 1000 may include a front panel assembly 1200, a middle panel assembly 1300, and a back panel assembly 1400. Front panel assembly 1200 may include a front roof panel assembly 1260, a front wall panel assembly 1240 that may have an opening 1242 for receiving a substrate, and a front base panel assembly 1220. Rear panel assembly 1400 may include a rear roof panel assembly 1460, a rear wall panel assembly 1440, and a rear base panel assembly 1420. Intermediate panel assembly 1300 may include a first intermediate enclosure panel assembly 1340, an intermediate wall and roof panel assembly 1360, and a second intermediate enclosure panel assembly 1380, and an intermediate base panel assembly 1320.

Additionally, as depicted in fig. 1A, the intermediate panel assembly 1300 may include a first printhead management system substantially low-particle environment, and a second printhead management system auxiliary panel assembly (not shown). Various embodiments of the auxiliary enclosure constructed as part of the gas enclosure assembly may be sealingly separated from the working volume of the gas enclosure system. For various embodiments of systems and methods of the present teachings, the secondary enclosure may enclose less than or equal to about 1% of the enclosure volume of the gas enclosure system. In various embodiments of the systems and methods of the present teachings, the secondary enclosure may enclose less than or equal to about 2% of the enclosure volume of the gas enclosure system. For various embodiments of the systems and methods of the present teachings, the auxiliary enclosure may be less than or equal to about 5% of the enclosure volume of the gas enclosure system. In various embodiments of the systems and methods of the present teachings, the auxiliary enclosure may be less than or equal to about 10% of the enclosure volume of the gas enclosure system. In various embodiments of the systems and methods of the present teachings, the auxiliary enclosure may be less than or equal to about 20% of the enclosure volume of the gas enclosure system. If an opening of the auxiliary enclosure to the ambient environment containing the reactive gas is instructed to perform, for example, a maintenance procedure, the separation of the auxiliary enclosure from the working volume of the gas enclosure may prevent contamination of the entire volume of the gas enclosure. Further, given the relatively small volume of the secondary enclosure, the recovery time of the secondary enclosure may take significantly less time than the recovery time of the entire printing system enclosure, as compared to the printing system enclosure portion of the gas enclosure.

As depicted in fig. 1B, gas enclosure assembly 1000 may include a front base plate assembly 1220, a middle base plate assembly 1320, and a rear base plate assembly 1420, which when fully constructed form a continuous base or chassis upon which printing system 2000 may be mounted. In a similar manner as described for gas enclosure assembly 100 of fig. 1A, the various frame members and panels comprising front panel assembly 1200, middle panel assembly 1300, and rear panel assembly 1400 of gas enclosure assembly 1000 may be joined around printing system 2000 to form a printing system enclosure. Front panel assembly 1200 may be contoured around the installed printing system 2000 to form a first tunnel enclosure section of gas enclosure. Similarly, back panel assembly 1400 may be shaped around printing system 2000 to form a second tunnel enclosure section of gas enclosure. Additionally, the middle panel assembly 1300 may be contoured around a bridge section of the printing system 2000 to form a gas-enclosed bridge enclosure section. Meanwhile, the first tunnel enclosure section, the second tunnel section, and the bridge enclosure section may form a print enclosure section. As will be discussed in greater detail herein, in accordance with the present teachings, the auxiliary enclosure may be sealingly separated from the printing system enclosure during, for example, a printing process, in order to perform various measurement and maintenance tasks with little or no interruption to the printing process.

Further, a fully constructed gas enclosure assembly (such as gas enclosure assembly 1000), when integrated with various environmental control systems, may form various embodiments of a gas enclosure system, including various embodiments of an OLED printing system (such as printing system 2000). According to various embodiments of a gas enclosure system of the present teachings, environmental control of an interior volume defined by a gas enclosure assembly can include: control of lighting (e.g., by number and arrangement of lamps of a particular wavelength), control of particulate matter using various embodiments of the particle control system, control of reactive gas species using various embodiments of the gas purification system, and temperature control of the gas enclosure assembly using various embodiments of the thermal regulation system.

The printing system shown in expanded view in fig. 1C (such as printing system 2000 of fig. 1B) may be comprised of several devices and apparatuses that allow for the reliable placement of ink drops on specific locations on a substrate. These devices and equipment may include, but are not limited to, a printhead assembly, an ink delivery system, a motion system for providing relative motion between the printhead assembly and a substrate, a substrate support apparatus, a substrate loading and unloading system, and a printhead management system.

The printhead assembly may include at least one inkjet head having at least one orifice capable of ejecting ink drops at a controlled rate, velocity, and size. The ink jet head is fed by an ink supply system that provides ink to the ink jet head. As shown in the expanded view of fig. 1C, the printing system 2000 can have a substrate (such as substrate 2050) that can be supported by a substrate support device (such as a chuck, for example, but not limited to, a vacuum chuck, a substrate floating chuck having a pressure port, and a substrate floating chuck having both vacuum and pressure ports). In various embodiments of the systems and methods of the present teachings, the substrate support apparatus can be a substrate floatation table. As will be discussed in greater detail later herein, the substrate floatation table 2200 of fig. 1C can be used to support a substrate 2050 and, in conjunction with a Y-axis motion system, can be part of a substrate transport system that provides frictionless transport of the substrate 2050. As will be discussed in greater detail herein, the Y-axis motion system of the present teachings can include a first Y-axis support beam 2351 and a second Y-axis support beam, which can include a gripper system (not shown) for holding a substrate. The Y-axis motion may be provided by a linear air bearing or a linear mechanical system. The substrate floatation table 2200 of the printing system 2000 illustrated in fig. 1B and 1C can define travel of a substrate 2050 through the gas enclosure assembly 1000 of fig. 1A during a printing process.

Fig. 1C generally illustrates an example of a substrate floatation table 2200 for a printing system 2000 that may include a floating transport of a substrate, which may have a porous media that provides floatation. In the example of fig. 1C, a conveyor or other transport member may be used to position a substrate 2050 in the input area 2201 of the substrate floatation table 2200, such as on the transport member. The conveyor may position the substrate 2050 at a particular location within the printing system, such as using mechanical contact (e.g., using an array of pins, a tray, a support frame configuration) or using a gas cushion to controllably float the substrate 2050 (e.g., an "air bearing" table configuration). The printing region 2202 of the substrate floatation table 2200 can be used to controllably deposit one or more layers on the substrate 2050 during fabrication. Printing region 2202 can also be coupled to an output region 2203 of substrate floatation table 2200. The conveyor may extend along the input region 2201, the printing region 2202, and the output region 2203 of the substrate floatation table 2200, and may reposition the substrate 2050 for various deposition tasks as needed, or may reposition the substrate 2050 during a single deposition operation. The controlled environment in the vicinity of the input area 2201, the print area 2202, and the output area 2203 may be universally shared.

The printing system 2000 of fig. 1C may include one or more printhead arrangements 2505, each having one or more printheads; for example of the nozzle printing, thermal jet, or inkjet type. One or more printhead devices 2505 can be coupled to or otherwise span an overhead (overhead) carriage, such as first X-axis carriage assembly 2301. For various embodiments of printing system 2000 of the present teachings, one or more printheads of one or more printhead arrangements 2505 may be configured to deposit one or more patterned organic layers on substrate 2050 in a "face-up" configuration of substrate 2050. Such layers may include: such as one or more of an electron injection or transport layer, a hole injection or transport layer, a blocking layer, or an emissive layer. Such materials may provide one or more electrically functional layers.

According to the floating scheme shown in fig. 1C, in examples where substrate 2050 is supported only by a gas cushion, a combination of positive gas pressure and vacuum may be applied through an arrangement of ports or using a distributed porous medium. Such a zone with pressure and vacuum control may effectively provide a fluid spring between the conveyor and the substrate. A combination of positive pressure and vacuum control may provide a fluid spring with a bi-directional stiffness. The gap that exists between the substrate (e.g., substrate 2050) and the surface may be referred to as the "fly height," and such height may be controlled or otherwise established by controlling the positive pressure and vacuum port conditions. In this manner, the substrate Z-axis height can be carefully controlled, for example, in the print region 2202. In some embodiments, mechanical retention techniques (such as pins or frames) may be used to limit lateral translation of the substrate when supported by the gas cushion. Such retention techniques may include the use of spring-loaded structures to reduce the transient forces imparted into the sides of the substrate while retaining the substrate; this may be beneficial because high force impacts between the laterally translated substrate and the holding means may cause the substrate to chip or even destructively crack.

In other cases, generally as shown in FIG. 1C, such as where precise control of fly height is not required, a pressure-only float zone may be provided along the conveyor or elsewhere, such as in input or output region 2100 or 2300. A "transition" zone may be provided, such as where the ratio of pressure to vacuum nozzle is increased or decreased in steps. In the illustrative example, there may be a substantially uniform height between the pressure-vacuum region, the transition region, and the pressure-only region, such that, within a tolerance, the three regions may be essentially in one plane. The flying height of the substrate elsewhere above the pressure-only zone may be greater than the flying height of the substrate above the pressure-vacuum zone, such as to allow sufficient height so that the substrate will not collide with the floating table in the pressure-only zone. In an illustrative example, the OLED panel substrate may have a flying height of between about 150 micrometers (μ) to about 300 μ over the pressure-only region, and then between about 30 μ to about 50 μ over the pressure-vacuum region. In an illustrative example, one or more portions of substrate floatation table 2200 or other fabrication apparatus may include

Air Bearings assembly supplied by Air Bearings (Aston, pa, usa).

The porous media can be used to create a distributed pressurized gas cushion for floating transport or support of substrate 2050 during one or more of printing, buffering, drying, or thermal processing. For example, a porous media "plate" (such as coupled to or included as part of a conveyor) can provide a "distributed" pressure to support the substrate 2050 in a manner similar to the use of a separate gas port. Without the use of large gas port apertures, the use of a distributed pressurized gas cushion may further improve uniformity and reduce or minimize the formation of non-uniformities or other visible defects (despite the use of a gas cushion) in certain situations, such as those where the use of relatively large gas ports for generating a gas cushion results in non-uniformities.

Porous media, such as having physical dimensions designated to occupy all of substrate 2050 or designated areas of the substrate (such as a display area or an area outside the display area), may be obtained, for example, from Nano TEM co. Such porous media may include: the orifice size is specified to provide a desired pressurized airflow over a specified area while reducing or eliminating the formation of non-uniformities or other visible defects.

Printing requires relative motion between the printhead assembly and the substrate. This can be done using a motion system (usually a gantry or split axis XYZ system). The printhead assembly may move on a stationary substrate (gantry), or both the printhead and the substrate may move in a split-axis configuration. In another embodiment, the printhead assembly may be substantially stationary; for example, in the X and Y axes, the substrate may be moved relative to the printhead in the X and Y axes with Z axis motion provided by the substrate support apparatus or by a Z axis motion system associated with the printhead assembly. As the printhead moves relative to the substrate, ink drops are ejected at the correct time to be deposited in the desired location on the substrate. A substrate loading and unloading system may be used to insert and remove substrates from the printer. Depending on the printer configuration, this may be done using a mechanical conveyor, a substrate floatation table with a conveyor assembly, or a substrate transfer robot with an end effector. The printhead management system may be made up of several subsystems that allow for such measurement tasks (such as checking nozzle firing and measuring drop volume, velocity, and trajectory from each nozzle in the printhead) and maintenance tasks (such as wiping or drying out the ink nozzle surfaces of excess ink, ejecting ink from the ink supply through the printhead into a waste pool to prime and clean the printhead, and replacing the printhead). Various embodiments of OLED printing systems may have various areas of influence and form factors, taking into account the various components that may comprise the OLED printing system.

With respect to fig. 1C, the printing system base 2100 can include a first riser 2120 and a second riser 2122 on which the bridge 2130 is mounted. For various embodiments of the printing system 2000, the bridge 2130 may support first and second

X-axis carriage assemblies

2301 and 2302, respectively, that span the bridge 2130, which first and second

X-axis carriage assemblies

2301 and 2302 may control movement of the first and second

print head assemblies

2501 and 2502. For the various embodiments of the printing system 2000, the first X-axis carriage assembly 2301 and the second X-axis carriage assembly 2302 may utilize a linear air bearing motion system that is inherently low particle generation. According to various embodiments of a printing system of the present teachings, an X-axis carriage may have a Z-axis moving plate mounted thereon. In fig. 1C, the first X-axis bracket assembly 2301 is depicted with a first Z-axis moving plate 2310, and the second X-axis bracket assembly 2302 is depicted with a second Z-axis moving plate 2312. Although fig. 1C depicts two carriage assemblies and two printhead assemblies, there may be a single carriage assembly and a single printhead assembly for various embodiments of printing system 2000. For example, one of the first and

second printhead assemblies

2501, 2502 may be mounted on an X, Z axis carriage assembly, and a camera system for inspecting features of the substrate 2050 may be mounted on a second X, Z axis carriage assembly. Various embodiments of the printing system 2000 may have a single printhead assembly, for example, one of the first and

second printhead assemblies

2501 and 2502 may be mounted on an X, Z axis carriage assembly, while a UV lamp for curing a packaging layer printed on the substrate 2050 may be mounted on a second X, Z axis carriage assembly. For various embodiments of printing system 2000, there may be a single printhead assembly (e.g., either of first printhead assembly 2501 and second printhead assembly 2502) mounted on an X, Z axis carriage assembly, while a heat source for curing a packaging layer printed on substrate 2050 may be mounted on a second carriage assembly.

In fig. 1C, each printhead assembly (such as first printhead assembly 2501 and second printhead assembly 2502 of fig. 1C) can have multiple printheads mounted in at least one printhead device, as depicted for first printhead assembly 2501 in a partial view depicting multiple printhead devices 2505. The printhead device may include: for example, but not limited to, fluidic and electronic connections to at least one printhead; each printhead has a plurality of nozzles or orifices capable of ejecting ink at a controlled rate, velocity, and size. For various embodiments of printing system 2000, the printhead assembly may include between about 1 and about 60 printhead devices, where each printhead device may have between about 1 and about 30 printheads in each printhead device. A printhead (e.g., an industrial inkjet head) can have between about 16 and about 2048 nozzles that can discharge a drop volume of between about 0.1pl and about 200 pl.

According to various embodiments of the gas enclosure system of the present teachings, given the absolute number of printhead devices and printheads, the first and second

printhead management systems

2701 and 2702 may be housed in an auxiliary enclosure that may be separated from the printing system enclosure during the printing process in order to perform various measurement and maintenance tasks with little or no interruption to the printing process. As can be seen in fig. 1C, it can be seen that the first printhead assembly 2501 is positioned relative to the first printhead management system 2701 in preparation for performing various measurement and maintenance processes that may be performed by the first printhead

management system devices

2707, 2709, and 2711. The

devices

2707, 2709, and 2711 may be any of a variety of subsystems or modules for performing various printhead management functions. For example,

devices

2707, 2709, and 2711 may be any of a drop measurement module, a printhead replacement module, a purge reservoir module, and a blotter module. As depicted in fig. 1C, the first printhead management system 2701 can have

devices

2707, 2709, and 2711 that can be mounted on a linear orbital motion system 2705 for positioning relative to the first printhead assembly 2501. Similarly, the various devices housed within the second printhead management system 2702 can be mounted on a linear orbital motion system 2706 for positioning relative to the first printhead assembly 2502.

With respect to various embodiments of a gas enclosure assembly having an auxiliary enclosure, referring again to fig. 1B, the auxiliary enclosure can be isolated from a first working volume (e.g., a printing system enclosure), as well as hermetically isolated from the first working volume. As depicted in fig. 1C, there may be 4 isolators on the printing system 2000; a first isolator setting 2110 (second not shown on the opposite side) and a second isolator setting 2112 (second not shown on the opposite side) that support the substrate floatation table 2200 of the printing system 2000. For the gas enclosure assembly of fig. 1B, a first isolator setting 2110 and a second isolator setting 2112 may be mounted in each of the respective isolator wall panels (e.g., the first isolator wall panel 1325 and the second isolator wall panel 1327 of the intermediate base panel assembly 1320). For the gas enclosure assembly 1000 of fig. 1B, the middle base assembly 1320 may include a first printhead management system auxiliary panel assembly 1330 and a second printhead management system auxiliary panel assembly 1370. FIG. 1B of gas enclosure assembly 1000 depicts a first printhead management system auxiliary panel assembly 1330 that may include a first back wall panel assembly 1338. Similarly, a second printhead management system auxiliary panel assembly 1370 is also depicted which may include a second rear wall panel assembly 1378. The first back wall panel assembly 1338 of the first print head management system auxiliary panel assembly 1330 may be constructed in a similar manner as shown for the second back wall panel assembly 1378. Second rear wall panel assembly 1378 of second printhead management system auxiliary panel assembly 1370 may be constructed from second rear wall frame assembly 1378 having a second seal support panel 1375 sealably mounted to second rear wall frame assembly 1378. The second seal support panel 1375 may have a second channel 1365 proximate a second end (not shown) of the base 2100. A second seal 1367 may be mounted on a second seal support panel 1375 around a second channel 1365. A first seal may be positioned and installed around the first channel of the first printhead management system auxiliary panel assembly 1330. Each channel in auxiliary panel assembly 1330 and auxiliary panel assembly 1370 may house a printhead management system platform, such as first and second printhead

management system platforms

2703 and 2704 of fig. 1C, through the channel. In order to sealably isolate the auxiliary panel assembly 1330 and the auxiliary panel assembly 1370, channels (such as the second channel 1365 of fig. 1B) must be sealable according to the present teachings. It is contemplated that various seals (such as, for example, an inflatable seal, a bellows seal, and a lip seal) may be used to seal a channel (such as, for example, second channel 1365 of fig. 1B) around a printhead management system platform secured to a printing system base.

First printhead management system auxiliary panel assembly 1330 and second printhead management system auxiliary panel assembly 1370 may include first printhead assembly opening 1342 of first floor panel assembly 1341 and second printhead assembly opening 1382 of second floor panel assembly 1381, respectively. The first floor panel assembly 1341 is depicted in fig. 1B as a portion of the first intermediate enclosure panel assembly 1340 of the intermediate panel assembly 1300. The first floor panel assembly 1341 is the same panel assembly as the first intermediate surrounding panel assembly 1340 and the first printhead management system auxiliary panel assembly 1330. Second floor panel assembly 1381 is depicted in fig. 1B as part of second intermediate enclosure panel assembly 1380 of intermediate panel assembly 1300. Second floor panel assembly 1381 is the same panel assembly as second intermediate enclosure panel assembly 1380 and second printhead management system auxiliary panel assembly 1370.

As previously discussed herein, the first printhead assembly 2501 can be housed in a first printhead assembly enclosure 2503, while the second printhead assembly 2502 can be housed in a second printhead assembly enclosure 2504. In accordance with the systems and methods of the present teachings, the first and second

printhead assembly enclosures

2503, 2504 can have openings at the bottom that can have edges (not shown) so that various printhead assemblies can be positioned for printing during the printing process. Additionally, the portions of the first printhead assembly enclosure 2503 and the second printhead assembly enclosure 2504 forming the housing may be constructed as previously described for the various panel assemblies, thereby enabling the frame assembly members and panels to provide an air-tight sealed enclosure.

A compressible gasket, which may additionally be used to hermetically seal various frame members, may be secured around each of the first and second

printhead assembly openings

1342, 1382, or alternatively around the edges of the first and second

printhead assembly enclosures

2503, 2504.

The compressible gasket material may be selected from, for example, without limitation, any class of closed cell polymeric materials (also referred to in the art as an expanded rubber material or an expanded polymeric material) in accordance with the present teachings. Briefly, closed cell polymers are prepared in such a way as to enclose a gas in discrete pores; wherein each discrete hole is closed by a polymeric material. Desirable properties of compressible closed-cell polymer gasket materials for hermetic sealing of frame and panel components include, but are not limited to, their resistance to chemical attack over a wide range of chemical species, their excellent barrier properties, their resiliency over a wide range of temperatures, and their resistance to permanent compression set. Generally, closed cell polymeric materials have higher dimensional stability, lower coefficient of moisture absorption, and higher strength than open cell polymeric materials. Various types of polymeric materials from which the closed cell polymeric material may be made may include, for example and without limitation, silicone, neoprene, ethylene-propylene-diene terpolymers (EPT); polymers and composites made using ethylene-propylene-diene monomer (EPDM), vinyl nitrile (vinyl nitrile), styrene-butadiene rubber (SBR), and various copolymers and mixtures thereof.

In addition to closed cell compressible gasket materials, another example of a class of compressible gasket materials having desirable properties for constructing embodiments of gas enclosure assemblies according to the present teachings includes a class of hollow extruded compressible gasket materials. Hollow extruded gasket materials, which are a class of materials, have desirable properties including, but not limited to, their resistance to chemical attack over a wide range of chemical species, their good barrier properties, their elasticity over a wide range of temperatures, and their resistance to permanent compression set. Such hollow extruded compressible gasket materials may use various form factors such as, for example, without limitation, U-shaped apertures, D-shaped apertures, square apertures, rectangular apertures, and any of various conventional form factor hollow extruded gasket materials. Various hollow extruded gasket materials can be made from the polymeric materials used for closed cell compressible gasket manufacture. For example, but not limiting of, various embodiments of the hollow extrusion gasket may be made of silicone, neoprene, ethylene-propylene-diene terpolymer (EPT); polymers and composites made using ethylene-propylene-diene monomer (EPDM), vinyl nitrile, styrene-butadiene rubber (SBR), and various copolymers and mixtures thereof. The compression of such a hollow bore gasket material should not exceed a 50% tolerance in order to maintain the desired properties. It is contemplated that various types of inflatable seals may be used: the printhead assembly is sealed using a first printhead assembly interface gasket 1345 and a second printhead assembly interface gasket 1385. Such inflatable seals can provide rapid sealing and unsealing during processing, and are fabricated from low contamination materials (such as low particle generating materials, low outgassing polymeric materials, such as silicone, neoprene, and butyl rubber materials).

As depicted in fig. 1B, the first and second printhead

assembly interface washers

1345, 1385 can be secured around the first and second

printhead assembly openings

1342, 1382, respectively. During various printhead measurement and maintenance procedures, the first and

second printhead assemblies

2501 and 2502 may be positioned by the first and second X, Z

axis carriage assemblies

2301 and 2302, respectively, above the first and second

printhead assembly openings

1342 and 1382, respectively, of the first and second

floor panel assemblies

1341 and 1381, respectively. In this regard, for various printhead measurement and maintenance processes, first and

second printhead assemblies

2501, 2502 may be positioned above first and second

printhead assembly openings

1342, 1382 of first and second

floor panel assemblies

1341, 1381, respectively, without covering or sealing first and second

printhead assembly openings

1342, 1382. The first X, Z axis carriage assembly 2301 and the second X, Z axis carriage assembly 2302 may interface the first printhead assembly enclosure 2503 and the second printhead assembly enclosure 2504, respectively, with the first printhead management system auxiliary panel assembly 1330 and the second printhead management system auxiliary panel assembly 1370, respectively. This docking may effectively close the first and second

printhead assembly openings

1342, 1382 during various printhead measurement and maintenance procedures without the need to seal the first and second

printhead assembly openings

1342, 1382. For various printhead measurement and maintenance procedures, interfacing may include the formation of gasket seals between the printhead assembly enclosure and each of the printhead management system panel assemblies. In conjunction with sealable closure channels (such as the second channel 1365 and complementary first channel of fig. 1B), when the first and second

printhead assembly enclosures

2503 and 2504 interface with the first and second printhead management system

auxiliary panel assemblies

1330 and 1370 to sealably close the first and second

printhead assembly openings

1342 and 1382, the resultant bonded structure is hermetically sealed.

In addition, in accordance with the present teachings, the auxiliary enclosure can be separated from, for example, another internal enclosure volume (such as a printing system enclosure) and the exterior of the gas enclosure assembly by sealably closing the passageway (such as first printhead assembly opening 1342 and second printhead assembly opening 1382 of fig. 1B) using a structural closure. In accordance with the present teachings, the structural closure may include various sealable coverings for the openings or passageways; such openings or passageways include non-limiting examples of surrounding panel openings or passageways. According to systems and methods of the present teachings, a door may be used to: any structural closure that reversibly covers or reversibly sealably closes any opening or passageway is used with pneumatic, hydraulic, electrical, or manual actuation. Thus, doors may be used to reversibly cover or reversibly sealably close the first and second

printhead assembly openings

1342, 1382 of fig. 1B.

In an expanded view of the printing system 2000 of fig. 1C, various embodiments of the printing system may include a substrate floatation table 2200 supported by a substrate floatation table base 2220. The substrate floatation table base 2220 may be mounted on the printing system base 2100. Substrate floatation table 2000 of the OLED printing system can support substrate 2050 and define a travel through gas enclosure assembly 1000 through which substrate 2050 can move during printing of the OLED substrate. The Y-axis motion system of the present teachings can include a first Y-axis support beam 2351 and a second Y-axis support beam, which can include a gripper system (not shown) for holding a substrate, which will be discussed in greater detail herein. The Y-axis motion may be provided by a linear air bearing or a linear mechanical system. In this regard, a motion system is incorporated; as depicted in fig. 1C, a Y-axis motion system, substrate floatation table 2200, can provide frictionless transport of substrate 2050 through a printing system.

Fig. 1D depicts a first print management system 2701 housed within a first print management system auxiliary panel assembly 1330 in accordance with various embodiments of gas enclosure assemblies and systems of the present teachings. As depicted in fig. 1D, auxiliary panel assembly 1330 is shown in cross-section to more clearly see the details of first printhead management system 2701. The

devices

2707, 2709, and 2711 may be various subsystems or modules for performing various functions in accordance with various embodiments of a printhead management system (such as the first printhead management system 2701 of figure 1D) of the present teachings. For example,

devices

2707, 2709, and 2711 can be drop measurement modules, printhead wash tank modules, and blotter modules. As depicted in fig. 1D, printhead exchange module 2713 may provide a location for docking at least one printhead device 2505. In various embodiments of the first printhead management system 2701, the first printhead management system auxiliary panel assembly 1330 can be maintained to maintain the same environmental specifications of the gas enclosure assembly 1000 (see fig. 1A). The first printhead management system auxiliary panel assembly 1330 can have a conveyor 2530, the conveyor 2530 positioned to perform tasks associated with various printhead management processes. For example, such subsystems may have various parts that are naturally consumable and require replacement, such as replacing blotters, inks, and waste reservoirs. A carrier may be used to package the various consumable portions in preparation for insertion (e.g., in a fully automated mode). As a non-limiting example, the blotter paper may be packaged in a tube format that can be easily inserted into a blotting module for use. As another non-limiting example, the ink may be packaged in a replaceable reservoir, as well as in a cartridge format for use in a printing system. Various embodiments of a waste receptacle may be packaged in a cartridge format that can be easily inserted into a wash tank module for use. In addition, portions of various components of the printing system subject to constant use may need to be replaced periodically. During the printing process, advantageous management of the printhead assembly (such as, but not limited to, exchange of the printhead device or printhead) may be desirable. The printhead replacement module may have a portion (such as a printhead device or printhead) that can be easily inserted into the printhead assembly for use. A drop measurement module for checking nozzle firing and measuring based on optical detection of drop volume, velocity, and trajectory from each nozzle may have sources and detectors that may need to be periodically replaced after use. A carrier may be used to package various consumable and highly available portions in preparation for insertion (e.g., in a fully automated mode). The conveyor 2530 can have an end effector 2536 mounted to an arm 2534. Various embodiments of end effector configurations may be used, for example, blade-type end effectors, clamp-type end effectors, and gripper-type end effectors. Various embodiments of the end effector may include mechanical gripping and clamping and pneumatic or vacuum assist assemblies to actuate portions of the end effector or otherwise hold the print head device or a print head from the print head device.

Regarding replacement of a print head device or print head, the print head replacement module 2713 of the print head management system 2701 of fig. 1D may include a docking station for a print head device having at least one print head, and a storage container for the print head. While each printhead assembly (see fig. 1B) may include between about 1 and about 60 printhead devices, and while each printhead device may have between about 1 and about 30 printheads, various embodiments of printing systems of the present teachings may have between about 1 and about 1800 printheads. In various embodiments of the printhead replacement module 2713, although the printhead arrangement is docked, individual printheads mounted to the printhead arrangement may be maintained in an operating condition when not in use in a printing system. For example, when placed in a docking station, each print head on each print head device may be connected to an ink supply and electrically connected. Power may be supplied to the individual printheads on the individual printhead devices so that periodic firing pulses may be applied to the individual nozzles of the individual printheads at docking to ensure that the nozzles remain primed and do not clog. Conveyor 2530 of FIG. 1D may be positioned proximate printhead assembly 2500. As depicted in fig. 1D, the printhead assembly 2500 may dock above the first printhead management system auxiliary panel assembly 1330. During the process of replacing the printhead, the conveyer 2530 can remove the target portion from the printhead assembly 2500; a print head or a print head arrangement with at least one print head. The transporter 2530 can retrieve replacement parts (such as a print head device or a print head) from the print head replacement module 2713 and complete the replacement process. The removed portion may be placed into the printhead replacement module 2713 for retrieval.

In fig. 2A, the gas enclosure system 500 may have: a first tunnel enclosure section, which may have an access door 1242 for receiving a substrate; bridge enclosure section 1300; and a second tunnel enclosing section, which together may form a printing system enclosure. Additionally, the gas enclosure system 500 may have an auxiliary enclosure 1330. The auxiliary enclosure 1330 may be sealably separable from the printing system enclosure of the gas enclosure system 500. For example, during a printing process, the auxiliary enclosure 1330 may be sealably separated from the printing system enclosure of the gas enclosure system 500 for performing various measurement and maintenance tasks with little or no interruption to the printing process. As will be discussed in more detail in the discussion of fig. 8 that follows herein, purged inert gas from a purging system (such as purging system 3130 of fig. 8) may be circulated into the printing system enclosure of gas enclosure system 500 and into the auxiliary enclosure 1300.

For various embodiments of a printing system of the present teachings, a printhead assembly may include between about 1 and about 60 printhead devices. Recall that the printhead arrangement may comprise: for example, but not limited to, fluidic and electronic connections to at least one printhead; each printhead having a plurality of nozzles or orifices capable of ejecting ink at a controlled rate, speed, and size, wherein each printhead assembly may have between about 1 and 30 printheads in each printhead assembly. A printhead (e.g., an industrial inkjet head) can have between about 16 and about 2048 nozzles that can discharge a drop volume of between about 0.1pl and about 200 pl. Given the absolute number of print head devices and print heads, the secondary enclosure may house various embodiments of the print head management system. In accordance with the present teachings, the auxiliary enclosure may be separate from the printing system enclosure during the printing process in order to perform various measurement and maintenance tasks, such as, but not limited to, various devices and equipment using the printhead management system. Also, various measurement and maintenance tasks may be performed with little or no interruption to the printing process.

FIG. 2B depicts a perspective view of an auxiliary enclosure 1330 of a gas enclosure system according to various embodiments of the present teachings. The auxiliary enclosure 1330 may be an embodiment of an auxiliary enclosure that may be utilized with, for example, but not limited to, various gas enclosure systems of the present teachings, such as the gas enclosure system 1000 of FIG. 1A and the gas enclosure system 500 of FIG. 2A. As shown in fig. 2B, auxiliary enclosure 1330 can have a printhead management system platform 2703, and the printhead 2703 can have a linear rail system 2705 for positioning various devices and equipment for various measurement and maintenance processes relative to the various printhead devices of the printhead assembly. For example, in the partially exploded view of FIG. 2B, a printhead assembly 2500 is shown positioned over a printhead assembly opening 1350. Printhead assembly 2500 can have multiple printhead devices, such as 2505A, 2505B, and 2505C shown in fig. 2C. First motion system stage 2800A and second motion system stage 2800B may be used to position various devices and equipment mounted on the motion system stage for various measurement and maintenance procedures relative to each of the plurality of printhead devices of printhead assembly 2500.

The partially exploded view of fig. 2C depicts a top perspective view of the printhead management system 2700 in relation to the printhead assembly 2500. As depicted in fig. 2C, first motion system stage 2800A and second motion system stage 2800B may move along the Y-axis direction on linear rail system 2705. In this manner, linear rail system 2705 may position the various devices and equipment mounted on the motion system platform relative to the

respective printhead devices

2505A, 2505B, and 2505C of printhead assembly 2500. First motion system platform 2800A may support a first X-axis motion system platform 2810A, which first X-axis motion system platform 2810A may have a first X-axis linear rail system 2820A. The first X-axis linear rail system 2820A may move various devices mounted on the first X-axis motion system platform 2810A in a direction orthogonal to the direction of the first motion system platform 2800A on the linear rail system 2705. Similarly, a second motion system platform 2800B may support a second X-axis motion system platform 2810B, which second X-axis motion system platform 2810B may have a second X-axis linear track system 2820B. Second X-axis linear track system 2820B may move various devices mounted to second X-axis motion system platform 2810B in a direction orthogonal to the direction of second motion system platform 2800B on linear track system 2705. In this regard, the X, Y motion of first motion system stage 2800A and first X-axis motion system stage 2810A and the X, Y motion of second motion system stage 2800B and second X-axis motion system stage 2810B may provide precise X, Y positioning of various devices and apparatuses relative to each of

printhead devices

2505A, 2505B, and 2505C.

As depicted in fig. 2C, various devices mounted on first X-axis motion system platform 2810A of first motion system platform 2800A may include: cleaning

baths

2707A, 2707B, and 2707C for each of

printhead arrangements

2505A, 2505B, and 2505C, and a blotting station 2709. Depicted in FIG. 2C for providing calibration information is a first drop measurement module 2711A mounted on a first X-axis motion system platform 2810A of first motion system platform 2800A and a second drop measurement module 2711B mounted on a second X-axis motion system platform 2810B of second motion system platform 2800B. The first drop measurement system 2711A may be based on, for example, but not limited to, print drops that drop onto a film from respective nozzles of respective printheads of respective printhead devices under specified conditions and image the film. Information (such as drop volume, velocity, and trajectory) may be acquired by image analysis of the data thus acquired. Alternatively, second droplet measurement system 2711B may be based on, for example, but not limited to, an optical measurement system. For example, laser scattering techniques, such as Phase Doppler Analysis (PDA) and Phase Doppler Interferometry (PDI), may be used to determine drop volume, velocity, and trajectory of individual drops from individual nozzles of individual printheads of individual printhead devices.

FIG. 3 depicts the Y-axis motion system depicted in FIG. 3 as mounted to a Y-axis beam 2350, which may be, for example, a granite beam, in accordance with the present teachings. As depicted in the coordinate system, a substrate (such as 2050) mounted on floating stage 2200 may travel in the +/-Y-axis direction. The floating stage 2200 provides frictionless, low-particle generation substrate support of a substrate 2050 having a precise Z-axis fly height, while the Y-axis motion system 2600 provides frictionless, low-particle Y-axis transport of the substrate 2050 relative to a printhead assembly (such as printhead assembly 2501 of fig. 1C).

The various embodiments of the low particle generation Y-axis motion system of the present teachings utilized in conjunction with a floating stage may be compared to, for example, a chuck mounted on a large turntable. In the case of suction cups mounted on large turrets, large motors would be required in the operation of the large turrets, which would result in significant heat dissipation and particle generation due to the movement of the solid parts against the solid parts. With various embodiments of the gripper system of the present teachings, the only inertia in the system is the mass of the substrate and gripper assembly, such that any linear motor required for Y-axis motion is substantially smaller than a chuck mounted on a turntable.

Moreover, the inventors have discovered that although the Y-axis beam 2350 is fabricated to provide a surface that is level with and parallel to a high degree, the Y-axis beam may create a shift in travel that may be unacceptable for the intended use with respect to the accuracy of the orientation of the substrate relative to the theta-Z (θ -Z) axis during Y-axis travel. For example, but not limited to, printing ink into pixels of an OLED device substrate is a process that requires precise orientation of the substrate in the axis of travel for which beams manufactured to achieve high tolerances of flatness and parallelism can still produce unacceptable shifts in substrate orientation during travel. Thus, various embodiments of the Y-axis motion system 2600 of the present teachings utilizing an air bearing motion system for transporting the Y-axis carriage assembly 2620 may provide reliable, accurate low particle generation Y-axis transport of substrates, providing operation at high speeds with rapid acceleration and deceleration, and eliminating the need for dissipation of excessive thermal contamination in the gas enclosure system. Additionally, gripper motion control component 2650 of Y-axis motion system 2600 can provide dynamic rotation of the orientation of the substrate about the theta-Z (θ -Z) axis during Y-axis travel to maintain high accuracy of substrate orientation parallel to the travel axis. Accordingly, the gripper motion control component 2650 of the Y-axis motion system 2600 can maintain substrate orientation in a horizontal plane determined, for example, by the fly height of the substrate, with high accuracy parallel to the Y-axis travel direction.

As shown in fig. 3, various embodiments of the linear Y-axis motion system 2600 can include a substrate gripper assembly 2610, a Y-axis carriage assembly 2620, and a gripper motion control assembly 2650. In fig. 3, the gripper assembly 2610 may include a substrate gripping surface, such as, for example, but not limited to, a vacuum chuck bar 2612, which may be supported on a substrate gripper frame 2614. The substrate gripper frame 2614 may be mounted to a Y-axis carriage assembly 2620 of the Y-axis motion system assembly 2600. In fig. 3, the first and second

air bearing positioners

2628A and 2628B of the Y-axis carriage assembly 2620 are indicated as being mounted to first and second carriage arms (caddle arm) 2622A and 2622B, respectively, the first and

second carriage arms

2622A and 2622B being part of a plurality of air bearings that support the Y-axis carriage assembly 2620. The Y-axis carriage assembly 2620 may use a brushless linear motor to translate in the +/-Y-axis direction. As will be discussed in more detail later herein, the gripper motion control assembly 2650 may utilize a dual voice coil motor assembly (such as voice

coil motor assemblies

2630A and 2630B) and a pivot assembly 2660. Various embodiments of a gripper motion control assembly may include at least one voice coil motor and an air sleeve center pivot incorporating a position sensor and a motion controller. Various embodiments of the Y-axis motion system of the present teachings based on voice coil motors are highly reliable and can provide less than 1 micron of directional accuracy. In addition, such gripper assemblies with direct coupling of the substrate to the Y-axis motion system allow frictionless high speed operation with fast acceleration and fast deceleration using linear brushless motors for the transport of the Y-axis carriage assembly 2620 and dynamic rotation of the substrate about the orientation of the theta-Z (θ -Z) axis during Y-axis travel using the gripper motion control assembly 2650 to maintain high accuracy of substrate orientation parallel to the travel axis. Thus, various embodiments of a Y-axis motion system utilizing an air bearing gripper system can provide accurate low particle generation delivery of a substrate 2050 supported on floating stage 2200 by a printing system (such as printing system 2000 of fig. 1C). Such frictionless Y-axis motion systems for moving substrates may utilize one or two Y-axis rails. The service bundle carrier 2430 may be used for management of various service bundles, which may include: such as, but not limited to, fiber optic cables, electrical cables, wires, pipes, and the like. Various embodiments of service bundles according to the present teachings may be connected to a printing system to provide various optical, electrical, mechanical, and fluidic connections required to operate a functional printing system.

Fig. 4A is a top view of the Y-axis motion system 2600, showing the gripper assembly 2610, the Y-axis carriage assembly top plate 2624, and the gripper motion control assembly 2650. The gripper assembly 2610 may include a vacuum chuck bar 2612 mounted on a gripper frame 2614. The Y-axis carriage assembly top plate 2624 is depicted in fig. 4A as having a first end 2623 and a second end 2625. The gripper assembly 2610 and the Y-axis carriage assembly 2620 may be abutted by subassemblies of the gripper motion control assembly 2650. For example, first and second

voice coil assemblies

2630A and 2630B have first and second voice coil housings 2632A and 2623B, respectively, which first and second voice coil housings 2632A and 2623B may be secured to a Y-axis carriage assembly 2620 on one side of the voice coil assembly housing and to a gripper assembly 2610 on the opposite side of the voice coil housing. Additionally, the central pivot 2660 may include an air bearing housing 2662, which air bearing housing 2662 may be secured to the boss 2616 of the gripper assembly 2610. Fig. 4B is a partial top view of the air bearing Y-axis motion system 2600 of fig. 4A depicting an expanded top view of the second end 2625 of the Y-axis motion system 2600. In fig. 4B, an expanded top view of the gripper assembly 2610 and an expanded top view of the voice coil assembly 2630B are more apparent. Various embodiments of the vacuum chuck bar 2612 mounted on the gripper frame 2614 may include a plurality of vacuum slots 2613, wherein three of the plurality of vacuum slots 2613 are indicated in fig. 4B. The vacuum slots 2613 are spaced apart along the length of the vacuum chuck bar 2612 at intervals so that the vacuum chuck bar 2612 can easily engage and release a substrate, thereby eliminating the need for a dual-sided mechanical clamping of the substrate (such as a dual-sided mechanical clamping of a 2-finger or 3-finger clamping device). In addition to the first and second

air bearing positioners

2628A and 2628B of fig. 3 for supporting the Y-axis carriage assembly 2620, a second upper positioner 2628D may be mounted to the underside of the Y-axis carriage assembly top plate 2624 (see fig. 3 and 4B). A first upper positioner (not shown) may be symmetrically mounted below an opposing first end 2623 of Y-axis carriage assembly top plate 2624 proximate first mount arm 2622A (see fig. 4A).

As will be discussed in greater detail herein, in addition to the air bearing positioner for supporting the Y-axis carriage assembly 2620, the voice coil air bearing 2641 of the second voice coil assembly 2630B depicted in fig. 4B along with the voice coil air bearing (not shown) associated with the first voice coil assembly 2630A (see fig. 4A) may be used for vertical stability of the gripper assembly 2610. In the top view presentation of fig. 4B, a single air bearing is visible. Because of the preload of the voice coil air bearings in the voice coil assembly, such as

voice coil assemblies

2630A and 2630B of fig. 4A, the necessary system stiffness may be ensured. As depicted in the top view of fig. 4B, various embodiments of the Y-axis motion system of the present teachings can include a single air bearing. Various embodiments of systems and methods utilizing a single air bearing in a voice coil assembly may use, for example, but not limited to, gravity, vacuum, or magnetic preloading to preload the air bearing. Various embodiments of the Y-axis motion system may utilize an opposing second air bearing to provide bearing preload. Various embodiments of voice coil motor assemblies of the present teachings (such voice coil assemblies 2630B of fig. 4B) may include a voice coil housing 2633B that may be abutted to a Y-axis cradle 2620. As will be discussed in more detail herein, the voice coil holder frame mounting block 2648B of the voice coil assembly 2630B may be used to secure the voice coil assembly to the holder frame 2614. Voice coil assembly 2630B may also include a voice coil shaft 2634B, which may have a pivot screw 2635B and a retaining screw 2636B, as well as a set screw 2637B. Additionally, the voice coil assembly 2630B may have a linear encoder 2638B. Finally, the central pivot 2660 is an air sleeve configured to provide a rotational axis for reliable and accurate theta-Z (θ -Z) rotation for embodiments of the gripper motion control system 2650 of the present teachings. Although the components of voice coil assembly 2630B have been described, voice coil assembly 2630A may be similarly described.

Figure 5A is an isometric view of a carriage assembly, gripper motion control assembly, and gripper assembly of a Y-axis motion system according to various embodiments of systems and methods according to the present teachings. As depicted in fig. 5A, fig. 5A depicts a Y-axis carriage assembly 2620 with

first carriage arms

2622A and 2622B, respectively; the holder arms have first and

second positioners

2628A and 2628B, respectively, mounted thereon; such that the positioner is proximate the Y-axis beam 2350 (see fig. 3). First and

second holder arms

2622A and 2622B, and Y-axis carriage assembly side frames 2626 may be coupled to a Y-axis carriage assembly top plate 2624. The Y-axis carriage assembly side frame 2626 can have a first side 2627 proximate the Y-axis beam 2350 (see fig. 3) and a second side 2629 proximate the gripper frame 2614. The gripper motion control assembly 2650 may include first and second

voice coil assemblies

2630A and 2630B, respectively, and a central pivot assembly 2660. As previously discussed herein, the gripper motion control assembly 2650 is adjacent to both the Y-axis carriage assembly 2620 and the gripper assembly 2610; effectively abutting the Y-axis carriage assembly and the gripper assembly (see also fig. 4B). Because a substrate (such as the substrate 2050 of fig. 3) is held by the vacuum chuck rod 2612 mounted to the gripper frame 2614, dynamic angular (θ -Z) adjustments to the substrate may be made by the gripper motion control assembly 2650 as the Y-axis carriage assembly 2620 travels over the Y-axis beam 2350 (see fig. 3) to offset the effects of defects in the Y-axis beam. Thus, during Y-axis travel, the substrate may be maintained with high accuracy with respect to the orientation of the substrate about the theta-Z (θ -Z) axis during Y-axis travel using the gripper motion control assembly 2650 to maintain high accuracy in the orientation of the substrate parallel to the travel axis. Various embodiments of the gripper motion control assembly 2650 may maintain the orientation of the substrate traveling parallel to the Y-axis within +/-4300 micro radians. Accordingly, the gripper motion control component 2650 of the Y-axis motion system 2600 can maintain substrate orientation in, for example, a horizontal plane determined by the fly height of the substrate with high accuracy parallel to the Y-axis travel direction.

Fig. 5B depicts a long section perspective view through the Y-axis carriage assembly 2620 of fig. 5A, generally showing the gripper assembly 2610 mounted to the Y-axis carriage assembly 2620. In fig. 5B, first and second voice

coil motor assemblies

2630A and 2630B, respectively, are indicated, as well as a vacuum chuck bar 2612 on a gripper frame 2614, and a central pivot 2660. In fig. 3 and 5A, the first and second

air bearing positioners

2628A and 2628B of the Y-axis carriage assembly 2620 are indicated. In fig. 4B, the first and second air bearing positioners are depicted below the Y-axis carriage assembly top plate 2624. As shown in fig. 5B, the Y-axis carriage assembly side frame 2626 may have a plurality of air bearing locators, such as air bearing locators 2628E-2640H, mounted thereon. In addition to the air bearing locators on the pedestal arm and the top plate of the carriage assembly near the Y-axis beam 2350, a plurality of air bearing locators mounted on the Y-axis carriage assembly sideframes 2626 may provide bearing support between the sideframes 2626 and respective sides of the Y-axis beam 2350. Various embodiments of a Y-axis motion system of the present teachings (e.g., as generally shown in fig. 3-5B) may provide low particle generation, low heat generation transport through a substrate of a printing system.

Fig. 6 depicts a second side 2627 of the Y-axis carriage assembly side frame 2626 that is the side proximate the gripper frame 2614, and generally shows the Y-axis motion system subassembly including the gripper motion control assembly 2650 to which the gripper frame 2614 is not mounted. The first and second

voice coil assemblies

2630A and 2630B may be mounted at opposite top ends of the second side 2627 of the Y-axis carriage assembly sideframes 2626, and the center pivot 2660 may be mounted in a top center portion of the second side 2627 of the Y-axis carriage assembly sideframes 2626. The first and second

voice coil assemblies

2630A and 2630B may include first and second voice

coil assembly shafts

2634A and 2634B, respectively, and first and second voice

coil assembly housings

2632A and 2632B. Each of the first and second voice

coil assembly shafts

2634A and 2634B may have a set screw, respectively a first voice coil assembly set screw 2635A and a second voice coil assembly set screw 2637B, each having a shank extending into voice coil assembly set

screw holes

2621A and 2621B, respectively. Additionally, as depicted in fig. 6, each of the voice coil assembly shafts, first voice coil assembly shaft 2634A and second voice coil assembly shaft 2634B, may have a pivot screw and a retaining screw; pivot screw 2635A and retaining screw 2636A for first voice coil assembly shaft 2634A and pivot screw 2635B and retaining screw 2636B for first voice coil assembly shaft 2634B. For initial adjustment of the horizontal position of the gripper assembly and the substrate relative to the floating stage, the pivot screw and the retaining screw may be loosened for the first and second

voice coil assemblies

2630A and 2630B until the horizontal position of the gripper and the substrate are properly adjusted, and then the pivot screw and the retaining screw are tightened.

Voice coil assemblies

2630A and 2630B may be adjusted equally to adjust the position of the gripper assembly in +/-Z relative to the floating stage (see fig. 3), while

voice coil assemblies

2630A and 2630B may be adjusted unequally to adjust the position of the gripper assembly in theta-X (theta-X) relative to the floating stage (see fig. 3). As previously discussed herein, various embodiments of voice coil assemblies of the present teachings utilize a pair of air bearings, an upper or top air bearing (such as air bearing 2640A of first voice coil assembly 2630A and air bearing 2641A of second voice coil assembly 2630B) and an opposing bottom air bearing (such as air bearing 2640B of first voice coil assembly 2630A and air bearing 2641B of second voice coil assembly 2630B). Each bottom air bearing is used to preload each upper or top air bearing.

Figure 7A generally illustrates an isometric view of a voice coil assembly according to the present teachings. The voice coil assembly may include a voice coil housing 2632 that may have a first voice coil housing first side 2631 and an opposing voice coil housing second side 2633, and a voice coil shaft 2634. As previously discussed herein with respect to fig. 6, the voice coil shaft 2634 may include a pivot screw 2635 and a retaining screw 2636, as well as a set screw 2637, all of which may be used for initial vertical adjustment of the gripper assembly relative to the floating stage. In fig. 7B, the pivot screw 2635 and the retaining screw 2636 have been removed, such that a pivot through hole 2645 that receives the pivot screw 2635 and a through slot 2646 that receives the retaining screw 2636 are apparent. Voice coil assembly 2630 may have a pair of air bearings, such as an upper air bearing 2642A and an opposing or lower air bearing 2642B, the lower air bearing for preloading the upper air bearing. Voice coil assembly 2630 may include voice coil holder frame mounting blocks 2648, which voice coil holder frame mounting blocks 2648 may be used to secure the voice coil assembly to the holder frame (see fig. 4B). Alternatively, the voice coil assembly of the present teachings may include a linear encoder 2638 oriented in the X-direction. Various embodiments of the Y-axis motion system of the present teachings utilize a linear encoder head that allows the voice coil to be oriented within 1-2 microns in the X-direction relative to the carriage assembly, thereby providing dynamic adjustment in theta-Z (theta-Z) during transport of the substrate on the Y-axis beam using various embodiments of the Y-axis motion system of the present teachings. Additionally, for the various embodiments of the gripper control assembly 2650 of fig. 6, a master-slave control system may be used to control the first and second

voice coil assemblies

2630A and 2630B of fig. 6 such that if one voice coil responds to correcting the theta-Z (θ -Z) orientation, the other voice coil is controlled in an equal or balanced manner. Various embodiments of the gripper motion control assembly 2650 may maintain the orientation of the substrate traveling parallel to the Y-axis within +/-4300 micro radians. Accordingly, the gripper motion control component 2650 of the Y-axis motion system 2600 can maintain substrate orientation in, for example, a horizontal plane determined by the fly height of the substrate with high accuracy parallel to the Y-axis travel direction.

Fig. 8 is a top view of the Y-axis motion system 2600, similar to fig. 4A indicating the position of the cross-sectional views of fig. 8 and 9, showing the gripper assembly 2610, the Y-axis carriage assembly top plate 2624, and the gripper motion control assembly 2650.

FIG. 9 generally illustrates a cross-sectional view through the voice coil assembly; specifically designated in fig. 8, any description given herein with respect to the cross-sectional view of fig. 9, as with the cross-sectional view of voice coil assembly 2630B, is equally applicable to voice coil assembly 2630A. Depicted in fig. 9 is voice coil holder frame mounting block 2648B positioned between first and

second air bearings

2641A and 2641B of voice coil assembly 2630B. Associated with each of the first and

second air bearings

2641A and 2641B are air bearing

spherical pivots

2643A and 2643B, respectively. The air bearing spherical pivot 2643A associated with the first air bearing 2641A and the air bearing spherical pivot 2643B associated with the first air bearing 2641B allow the respective air bearings to float in theta-X (theta-X) and theta-Y (theta-Y) such that the first and

second air bearings

2641A, 2641B remain in a parallel arrangement relative to the mounting block 2648B. In addition to being positioned between first air bearing 2641A and second air bearing 2641B, voice coil holder frame mounting block 2648B is also secured to voice coil holder 2647. Voice coil retainer 2647 and the voice coil magnet base are housed inside voice coil housing second side 2633. Voice coil retainer 2647 is depicted in fig. 9 as being associated with voice coil magnet base 2649. During operation, the force of movement of voice coil magnet base 2649 is translated to voice coil magnet holder 2647, to voice coil gripper frame mounting block 2648B, and then thence to gripper frame 2614. As previously discussed herein, various embodiments of the gripper motion control assembly 2650 may use master-slave control of two voice coil assemblies such that the two voice coils are used in synchronization to maintain the gripper assembly orientation relative to the direction of travel. Also depicted in fig. 9 is a vacuum manifold 2618 of the gripper assembly 2610, the vacuum manifold 2618 being in flow communication with a vacuum groove 2617. As depicted in fig. 9, the plurality of vacuum slots depicted in fig. 4B may be in flow communication with a vacuum manifold 2618 via vacuum grooves 2617.

Fig. 10 generally illustrates a cross-sectional view through a center pivot assembly 2660 as designated in fig. 8. The pivot assembly 2660 may include an air sleeve housing 2662, which air sleeve housing 2662 may house a first air sleeve 2664A and a second air sleeve 2664B. First and

second air sleeves

2664A, 2664B may be configured about a central axis 2666; the use of two air sleeves imparts the necessary system stiffness. The first and

second air sleeves

2664A and 2664B may be fabricated from a porous material (such as porous graphite) to ensure that a uniform flow of gas (such as an inert gas) may be evenly distributed about the central axis 2666. Central shaft 2666 may be held by an upper clamp 2665 and a lower clamp 2667 that may be secured to a carriage assembly top plate 2624. The center pivot adapter plate 2669 may be configured to secure the air sleeve housing 2662 to the gripper frame 2614. In this regard, in response, any theta-Z (θ -Z) rotation of the air sleeve assembly 2660 due to movement of the carriage assembly is translated to the gripper assembly 2610. Also depicted in fig. 10 are a carriage assembly air bearing 2638D (see fig. 4B) and a carriage assembly air bearing 2638H (see fig. 5B).

As previously discussed herein, maintaining a controlled environment within a printing enclosure is paramount to various methods related to the manufacture of various OLED devices. As will be discussed in greater detail subsequently herein, in accordance with various embodiments of a gas enclosure system of the present teachings, environmental control of an interior volume defined by a gas enclosure assembly can include: control of lighting (e.g., by number and arrangement of lamps of a particular wavelength), control of particulate matter using various embodiments of the particle control system, control of reactive gas species using various embodiments of the gas purification system, and temperature control of the gas enclosure assembly using various embodiments of the thermal regulation system. One aspect of thermal conditioning relates to minimizing thermal load within the enclosed printing system, for example, as given by the design of the Y-axis motion system described previously herein.

In addition to the Y-axis motion system, and with respect to the schematic shown in fig. 11, minimizing thermal load may further include: the thermal load of the motor for controlling the movement of the Z-axis moving plate is minimized by utilizing pneumatic balancing. In fig. 11, a control loop 100 can be used to ensure that the current driven Z-axis motor 2305 can be optimized during operation (especially under load) because increasing the current into the Z-axis motor 2305 will increase the motor temperature. One disadvantage of such motor heating may be: loss of printing accuracy due to thermal expansion of the motor and motor assembly. Additionally, as previously mentioned herein, control of heat dissipation is one aspect of environmental control of a closed printing system. Thus, the control loop 100 of fig. 11 is shown to include a pneumatic balancing system 2309 that can compensate for the load on the Z-axis motor 2305 by providing an automated balancing force against the load to minimize motor current, thereby minimizing motor heating.

In FIG. 11, Z _cmd Input 105 is a commanded Z-axis position for a printhead assembly, such as first printhead assembly 2501 and second printhead assembly 2502 of fig. 1C. Referring to fig. 1C, recall that the first and

second printhead assemblies

2501 and 2502 may be mounted on the first and second Z-

axis moving plates

2310 and 2312, respectively. First and second Z-

axis moving plates

2310 and 2312 are mounted to first and second

X-axis bracket assemblies

2301 and 2302, respectively. In this regard, the various printhead assemblies can be positioned in the X, Z directions relative to a substrate (such as substrate 2050 of fig. 1C). In the exemplary process step (For example, but not limited to, a printing process), Z _cmd The input 105 may be provided by the motor controller C _M 110, and may compare the commanded Z-axis position i to a desired Z-axis position _cmd 115 to the motor drive D120 such that the Z-axis linear motor 2305 can move a Z-axis moving plate (such as the first and second Z-

axis moving plates

2310 and 2312 of fig. 1C). The encoder 2303 may be used to measure the exact position of the Z-axis moving plate in the Z-axis direction, where information about the exact Z-axis position may then be fed back to the motor controller C _M 110 until the command position has been reached. In addition, i may be _cmd 115 to a low pass filter LP 130, which low pass filter LP 130 may be used to filter current spikes and additionally gate the controller response. The low pass filter output 135 may be sent to the pneumatic controller C _P 140. Pneumatic controller C _P 140 may then calculate an optimization i _cmd 115 equilibrium pressure P _CB . During exemplary process steps, for example, but not limiting of, docking a printhead assembly with a docking gasket as previously described herein, as indicated in fig. 11, there is a counter sealing force F _S Required motor force F _M . While the additional motor force enables the seal to be maintained, it requires increased motor current, resulting in increased motor heating.

As depicted in fig. 11, to minimize the force F required to maintain the motor during sealing of the printhead assembly against the docking gasket _M The motor heating generated by the increased current can be utilized by utilizing the pneumatic balance force F _CB . Vertical sealing force F _S Can be detected by constantly detecting the current of the motor 2305. The sealing force F may be reported to the pneumatic controller Cp 140 _S The magnitude and direction of the pneumatic controller Cp 140 may calculate the required pneumatic reaction force and may command a balance force pressure P _CB 145 to a pressure regulator 150. The pressure regulator R150 may then supply the commanded pressure to the pneumatic balance system 2309 in order to apply the pneumatic reaction force F _CB . In accordance with the present teachings, the control circuit 100 functions in a manner such that all forces acting on the Z-axis assembly: secret keySealing force F _S Intrinsic tool environment force F _E Pneumatic reaction force F _CB Motor force F _M And gravity F _G The sum of (a) and (b) is 0.

FIG. 12A depicts the printing system 2000 showing the first X-axis carriage assembly 2301 and the second X-axis carriage assembly 2302 without the printhead assembly mounted thereon. In fig. 12B, a front view of an X-axis bracket assembly 2301 mounted to a bridge 2130 is depicted, wherein a pneumatic balancing system 2309 may include a first cylinder 2307A and a second cylinder 2307B. Although an example of the use of the control loop 100 is given for the process of interfacing a printhead assembly with a gasket, the control loop 100 may be used for several purposes. For example, during a printing operation, a pneumatic balance system (such as pneumatic balance system 2309) may operate in response to various embodiments of a pneumatic balance control loop to support the Z-axis moving plate and any associated loads in order to minimize current into motor 2305 of fig. 11 during printing. Additionally, various embodiments of a pneumatic balancing control loop (such as control loop 100 of fig. 11) may be used for parameter monitoring of a printing system. For example, the sliding of the Z-axis moving plate may change over time, creating increased friction due to wear and aging. Various embodiments of a pneumatic balancing control circuit and associated system may be used to offset the increased load on the Z-axis moving plate motor due to increased friction. As another non-limiting example, by a pneumatic controller C _P Monitored pressure changes may be monitored as a quality metric to initiate unscheduled maintenance of the Z-axis motion system before significant failure. It should be noted that while some examples are given for a particular carriage assembly, the various embodiments of the pneumatic balancing control circuit and associated system are generally applicable to any carriage assembly and any load of the present teachings.

As depicted in fig. 13, gas enclosure 1000A may house printing system 200A. Gas enclosure assembly 500A has features as described with respect to various embodiments of gas enclosure system 500 of fig. 18, while printing system 2000A may have all of the features described with respect to printing system 2000 of fig. 17. The printing system 2000A can have a printing system base 2100, which printing system base 2100 can be supported by at least two sets of separators, such as separator set 2110 including

separators

2110A and 2110B of fig. 13. The Y-axis motion system 2350 may be mounted on the printing system base 2100. The substrate 2050 may be floatingly supported by the substrate floating table 2200. The printing system base 2100 may support a first riser 2120 and a second riser 2122, and the bridge 2130 may be mounted on the first riser 2120 and the second riser 2122. The printing system bridge 2130 may support: a first X-axis carriage assembly 2301 on which printhead assembly 2500 may be mounted; a second X-axis carriage assembly 2302 may mount a camera assembly 2550 thereon. Additionally, the gas enclosure 1000A may have an auxiliary panel assembly 1330 that may enclose the printhead management system 2701, as well as a waste containment system for the bulk ink delivery system. Auxiliary panel assembly 1330 can be in flow communication with the remaining working volume of gas enclosure 1000A through printhead assembly opening 1342. Various embodiments of the bulk ink delivery system may be external to the gas enclosure 1000A and in flow communication with various embodiments of a local ink delivery system that may be proximate to the printhead assembly 2500 on the first X-axis carriage assembly 2301.

FIG. 14 is a schematic diagram of various embodiments of a bulk ink delivery system 3300 that may be in flow communication with a local ink delivery system 3500. Bulk Ink Delivery System (BIDS) 3300 may have a bulk ink supply system 3310, which bulk ink supply system 3310 may include a first BIDS ink supply line L in flow communication with a first ink source _B1 And a second BIDS ink supply line L in flow communication with a second ink source _B2 . First BIDS ink supply line L _B1 And a second BIDS ink supply line L _B2 May have a first BIDS ink supply relief valve V, respectively _B1 And a second BIDS ink supply relief valve V _B2 . For example, the first BIDS ink supply relief valve V may be used when the ink supply container needs to be replaced or refilled _B1 And a second BIDS ink supply relief valve V _B2 May be used to isolate the first and second ink supplies from the upstream line. First BIDS ink supply valve V _B3 Which is opened when the first ink supply container ink 1 is used. Similarly, theSecond BIDS ink supply valve V _B4 Which is opened when the second ink supply container ink 2 is used.

Although fig. 14 indicates two ink supplies, multiple ink supply containers may be included in the bulk ink supply system 3310 and may serve as a continuous supply of ink. For example, as shown in FIG. 14, when the level of ink in the first ink supply container ink 1 is at the low level indicator, the first BIDS ink supply safety valve V may be closed _B1 And the first BIDS ink supply valve V can be closed _B3 Thereby allowing the first ink supply container ink 1 to be isolated and refilled or replaced. After isolation of ink 1, a second BIDS ink supply relief valve V may be opened _B2 And the second BIDS ink supply valve V can be opened _B4 So that the second ink supply container ink 2 can serve as an ink supply source for a gas enclosure system (such as the gas enclosure system 500A of fig. 13). First BIDS ink supply line L _B1 And a second BIDS ink supply line L _B2 Two valves (as shown in fig. 14) may be used to join at the T-junction, or a three-way valve may be used. First BIDS ink supply line L _B1 Or one of the second BIDS ink supply lines may be connected to the third BIDS line L _B3 Flow communication, depending on which ink supply is in use. Third BIDS pipeline L _B3 May be associated with the first BIDS pump P _B1 In flow communication with the first BIDS pump P _B1 May be a pneumatic piston injector or a metering pump compatible with the chemistry of the ink used. During a process requiring ink flow from the bulk ink supply system 3310, the fifth BIDS valve V _B5 In an open position, allowing the third BIDS line L _B3 And a fourth BIDS line L _B4 To flow in between. Fourth BIDS pipeline L _B4 Passes through filter 3312 and communicates with fifth BIDS line L _B5 In flow communication, the fifth BIDS line L _B5 In flow communication with a degasser for removing dissolved gases from the bulk ink in the supply from bulk ink supply system 3310. Finally, after degassing, ink can flow through the flow connection with the local ink delivery system 3500Open sixth BIDS pipeline L _B6 . Sixth BIDS pipeline L _B6 May be controlled at the outlet by a suction valve (suction valve) located at the local ink delivery system 3500.

In addition to batch ink supply system 3310, batch ink delivery system 3300 may have a BIDS maintenance system 3330, which may include a solvent line, a seventh BIDS solvent line L _B7 And an inert gas line, an eighth BIDS gas line L _B8 Depicted in fig. 14 as utilizing a nitrogen source. Seventh BIDS solvent line L _B7 May have a second BIDS pump P _B2 Is in flow communication with the second BIDS pump P _B2 May be a pneumatic piston injector or a metering pump compatible with the chemistry of the solvent used. Seventh BIDS solvent line L _B7 And an eighth BIDS gas line L _B8 May each have a first BIDS maintenance system relief valve V _B6 And a second BIDS maintenance system relief valve V _B7 The first BIDS maintenance system relief valve V _B6 And a second BIDS maintenance system relief valve V _B7 In a normally closed position during processing, but may alternatively be opened during, for example, but not limited to, a maintenance procedure. For example, a BIDS valve, BIDS valve V, associated with the bulk ink supply system 3310 during a maintenance procedure _B1 To V _B5 Will remain in the closed position. If a maintenance procedure with solvent is to be carried out, the BIDS valve V can be opened _B6 、V _B8 And V _B10 Such that, the solvent line, the seventh BIDS solvent line L _B7 May be connected to the sixth BIDS pipeline L _B6 In flow communication, as previously described, the sixth BIDS line L _B6 In flow communication with the local ink delivery system 3500. Additionally, if inert gas is utilized during the maintenance process, the BIDS valve V can be opened _B7 、V _B9 And V _B10 Such that the inert gas line is the eighth BIDS solvent line L _B8 May be connected to the sixth BIDS pipeline L _B6 In flow communication, as previously described, the sixth BIDS line L _B6 In flow communication with the local ink delivery system 3500. It should be noted that the seventh BIDS solution is similar to that described for the bulk ink supply system 3310Agent line L _B7 And an eighth BIDS gas line L _B8 Two valves may be used to join at T-junction (as shown in FIG. 14) to ninth BIDS line L _B9 Are in flow communication. Likewise, the third BIDS pipeline L _B3 And ninth BIDS line L _B9 Two valves may be used to join at T-junction (as shown in FIG. 14) to fourth BIDS line L _B4 Are in flow communication. In any case, the 3-way valve may be used in a manner equivalent to T-junction using two valves.

As depicted in fig. 14, a local ink delivery system 3500 in accordance with various systems and methods of the present teachings can include a local ink supply system 3600, a printhead ink delivery system 3700, and a local ink waste assembly 3800. For various embodiments of the present teachings, the local ink-supply system 3600 may be via the sixth BIDS line L _B6 In flow communication with the bulk ink delivery system 3300, and the partial ink waste assembly 3800 can be via the tenth BIDS line L _B10 In flow communication with batch ink delivery system waste assembly 3340. Tenth BIDS pipeline L _B10 May have a third BIDS pump P _B3 The third BIDS pump P _B3 May be a pneumatic piston injector or a metering pump compatible with the chemistry of the waste removed from the printhead ink delivery system 3700.

In FIG. 15, a schematic diagram of various embodiments of a bulk ink delivery system 3301 is shown. Batch ink delivery system 3301 may be in flow communication with local ink delivery system 3501. For various embodiments of batch ink delivery system 3301, pump P _B1 May be a metering pump that can efficiently pump both liquid and gaseous fluids. In this regard, the maintenance system 3331 and the bulk ink supply system 3311 of the bulk ink delivery system 3301 may utilize a metering pump P _B1 And carrying out flow control. As depicted in fig. 15, the metering pump P _B1 Providing a controllable manifold system with three input lines with the possibility for three output lines; two of these lines are indicated in fig. 15, all controlled using metering pumps as indicated. The number of controllable input and output lines may vary according to various embodiments of the metering pump. Bulk ink delivery system of the present teachingsVarious embodiments of metering pumps utilized in embodiments of the system may have: properties such as, but not limited to, ability to control liquid and gaseous fluids, corrosion resistant polymer surfaces in contact with fluid flow for preventing corrosion and contamination, zero dead volume connections for preventing cross contamination, minimum hold-up volume for rapid priming using minimum volumes of various inks, and valves with suck-back capability may be included. Thus, various embodiments of the bulk ink delivery system 3301 may utilize fewer valves and pumps than various embodiments of the bulk ink delivery system 3300 of FIG. 14.

The Bulk Ink Delivery System (BIDS) 3301 of fig. 15 can have a bulk ink delivery system 3311, and the bulk ink delivery system 3311 can have a first BIDS ink supply line L in flow communication with a first ink source _B1 And a second BIDS ink supply line L in flow communication with a second ink source _B2 . First BIDS ink supply line L _B1 And a second BIDS ink supply line L _B2 Can be respectively controlled by a first BIDS valve V _B1 And a second BIDS valve V _B2 Control, as indicated in FIG. 15, the first BIDS valve V _B1 And a second BIDS valve V _B2 May be a multi-port metering pump P _B1 A part of the assembly of (1). In addition to providing flow control to the bulk ink supply system 3311, a given metering pump P _B1 Metering pumps P having the ability to controllably treat various fluids with minimal hold-up volume _B1 And may also be used to controllably handle the maintenance system 3331. For example, in FIG. 15, the third BIDS solvent supply line L _B3 Can be in flow communication with a solvent source, and a fourth BIDS gas supply line L _B4 Can be in flow communication with an inert gas source, e.g., a nitrogen source as indicated in fig. 15. Third BIDS solvent supply line L _B3 And a fourth BIDS gas supply line L _B4 Can be respectively supplied by a third BIDS solvent supply valve V _B3 And a fourth BIDS gas supply valve V _B4 And (5) controlling. As depicted in FIG. 15, third BIDS solvent supply line L _B3 And a fourth BIDS gas supply line L _B4 May be associated with the fifth BIDS pipeline L _B5 In flow communication, the fifth BIDS line L _B5 Valve V may be supplied by a fifth BIDS maintenance system _B5 And (5) controlling. As indicated in FIG. 15, fifth BIDS maintenance system supply valve V _B5 May be a multi-port metering pump P _B1 Part of the assembly of (a). Third BIDS solvent supply line L _B3 And a fourth BIDS gas supply line L _B4 Two valves may be used to join at the T-junction (as shown in fig. 15), or a 3-way valve may be used. Third BIDS solvent supply valve V _B3 And a fourth BIDS inert gas supply valve V _B4 In a normally closed position during processing, but may be selectively opened during a maintenance procedure, as will be described in more detail later herein.

With reference first to the various embodiments of the system and method of FIG. 15, for example, before the printing process has begun, the passage of ink lines through metering pump P can occur _B1 Actuation of the manifold system of (1). For example, once the ink supply is available from first ink supply reservoir ink 1, first BIDS ink supply line L _B1 Can be controlled by opening the first BIDS ink supply valve V _B1 And BIDS waste line valve V _BW While all other valves remain closed, actuated with ink from ink 1. For the valve state thus positioned, the first BIDS ink supply line L can be made _B1 In the first BIDS ink supply line L _B1 And a batch ink delivery system waste assembly 3341 through a BIDS waste line L _BW Is in fluid communication. After priming, the metering pump P can be switched on, for example during the initiation of a printing process _B1 First BIDS ink supply valve V _B1 And sixth BIDS valve V _B6 And all other valves are closed. With the valve state so positioned, first ink supply container ink 1 is in flow communication with batch ink delivery system 3301, and batch ink delivery system 3301 is in flow communication with local ink delivery system 3501. Second BIDS pipeline L _B2 Can be aligned with respect to actuating the first BIDS ink supply line L _B1 The given example utilizes ink priming from ink 2 in a similar manner.

Although FIG. 15 indicates two ink supplies, multiple ink supply containers may be included in the bulk ink supply system 3311 and may serve as a continuous supply of inkAnd (4) applying a source. For example, as shown in fig. 15, when the level of ink in ink 1 of the first ink supply container is at the low level indicator, the metering pump P may be turned off _B1 First BIDS ink supply valve V _B1 Thereby allowing the ink 1 of the first ink supply container to be isolated and refilled or replaced. After the isolation of the ink 1, the metering pump P can be switched on _B1 Second BIDS ink supply valve V _B2 So that the second ink supply container ink 2 can serve as an ink supply source for a gas enclosure system (such as the gas enclosure system 500A of fig. 13). First BIDS line ink supply L _B1 Or second BIDS ink supply line L _B2 May be connected to the sixth BIDS pipeline L _B6 Flow communication, depending on which ink supply is in use. The metering pump P can be turned on during a process that requires ink flow from the bulk ink supply system 3311 _B1 First BIDS ink supply valve V _B1 And sixth BIDS valve V _B6 While all other valves are closed, thereby allowing ink supply line L at the first BIDS _B1 And a sixth BIDS line L _B6 And flow between them. Sixth BIDS pipeline L _B6 Through filter 3312 and associated with seventh BIDS line L _B7 In flow communication, the seventh BIDS line L _B7 In flow communication with a degasser for removing dissolved gases from the bulk ink, for example, but not limited to, in the supply from bulk ink supply system 3311. Finally, after degassing, ink may flow through eighth BIDS line L in flow communication with local ink delivery system 3501 _B8 . And the sixth BIDS line L of the bulk ink supply system 3310 of FIG. 14 _B6 In contrast, when metering pumps (such as metering pump P of FIG. 15) _B1 ) While such control may be provided, the eighth BIDS pipeline L _B8 There is no need for a suckback valve located in the local ink delivery system 3500 (as shown in fig. 14).

As previously discussed herein, the bulk ink delivery system 3301 of fig. 15 may have a BIDS maintenance system 3331 in addition to the bulk ink supply system 3311. BIDS maintenance system 3331 can include a third BIDS solvent supply line L _B3 And a fourth BIDS gas supply lineL _B4 The third BIDS solvent supply line L _B3 And a fourth BIDS gas supply line L _B4 Can be respectively supplied by a third BIDS solvent supply valve V _B3 And a fourth BIDS inert gas supply valve V _B4 And (5) controlling. As depicted in fig. 15, third BIDS solvent supply line L _B3 And a fourth BIDS gas supply line L _B4 May be associated with the fifth BIDS pipeline L _B5 Are in flow communication. Fifth BIDS pipeline L _B5 Can be controlled by a metering pump P _B1 Fifth BIDS maintenance system supply valve V _B5 And (5) controlling. In addition, with respect to the bulk ink delivery system 3301 of FIG. 15, BIDS waste line L _BW May be in flow communication with batch ink delivery system waste assembly 3341. BIDS waste line L _BW Can be controlled by a metering pump P _B1 BIDS waste line valve V _BW And (5) controlling. Third BIDS solvent supply valve V _B3 Fourth BIDS gas supply valve V _B4 Fifth BIDS maintenance system supply valve V _B5 And BIDS waste line valve V _BW In a normally closed position during processing, but may be selectively opened during a maintenance procedure.

For example, during a maintenance procedure, the metering pump P associated with the bulk ink supply system 3311 _B1 BIDS valve of (1), BIDS valve V _B1 、V _B2 And V _B5 Will remain in the closed position. If a maintenance procedure with solvent cleaning is to be carried out, the BIDS valve V can be opened _B3 、V _B5 And V _BW Thereby enabling flow communication through a fifth BIDS line L that may be in flow communication with a bulk ink delivery system waste assembly 3341 _B5 Solvent priming is performed. After priming, the BIDS waste line valve V may be closed during a maintenance procedure utilizing, for example, solvent cleaning of lines within the local ink delivery system 3501 _BW And the BIDS valve V can be opened _B3 、V _B5 And V _B6 Thereby allowing solvent to flow through the sixth BIDS line L _B6 Fifth BIDS line L in flow communication _B5 . As previously described, the sixth BIDS pipeline L _B6 In flow communication with the local ink delivery system 3500, provides solvent flow through the local ink delivery system 3501, andfinally passes through a ninth BIDS pipeline L _B9 To batch ink delivery system waste assembly 3341. In addition, if a maintenance process using inert gas is implemented, the BIDS valve V may be opened _B4 、V _B5 And V _B6 So that the inert gas can flow through the sixth BIDS line L _B6 Fifth BIDS line L in flow communication _B5 . As previously described, the sixth BIDS pipeline L _B6 In flow communication with the local ink delivery system 3500.

As depicted in fig. 15, a partial ink delivery system 3501 in accordance with various systems and methods of the present teachings can include a partial ink supply system 3601, a printhead ink delivery system 3701, and a partial ink waste assembly 3801. For various embodiments of the present teachings, the local ink-supply system 3601 may be via an eighth BIDS line L _B8 In flow communication with the bulk ink delivery system 3301, and the partial ink waste assembly 3801 can be via a ninth BIDS line L _B9 In flow communication with batch ink delivery system waste assembly 3341. Ninth BIDS pipeline L _B9 May have a second BIDS pump P _B2 The second BIDS pump P _B2 May be a pneumatic piston injector or a metering pump compatible with the chemistry of the waste removed from the printhead ink delivery system 3701.

FIG. 16 depicts a schematic cross-sectional view of a gas enclosure system 500A that may include a gas enclosure 1000A and a local ink delivery system 3500. As previously described herein, a local ink delivery system 3500 according to various embodiments of the present teachings can include a local ink supply system 3600, a printhead ink delivery system 3700, and a local ink waste assembly 3800. As depicted in FIG. 16, the sixth BIDS pipeline L _E6 Can be controlled by a back suction valve V located in the local ink delivery system 3500 _P1 Control so that ink can be delivered directly to the bulk ink supply reservoir that is part of the local ink supply system 3600. In this regard, various embodiments of a bulk ink delivery system of the present teachings can bring the ink supply directly to the ink reservoir local ink supply system 3600, which ink reservoir local ink supply system 3600 can be in communication with a bulk ink reservoirIn flow communication, the bulk ink reservoir is in flow communication with a dispensing reservoir that is in flow communication with, for example, a plurality of printhead devices (such as printhead device 2505 of fig. 1C). As will be described in greater detail herein, various embodiments of printhead ink delivery system 3700 may utilize a dual stage ink delivery assembly. Further, the local ink waste assembly of the gas enclosure interior may be in flow communication with a bulk ink delivery system waste assembly that is part of a bulk ink delivery system. Thus, various embodiments of a bulk ink delivery system that may be substantially outside of the gas enclosure system may be in flow communication with a local ink delivery system inside the gas enclosure system in a manner that avoids running ink lines through the cable carrier to a printhead assembly (such as printhead assembly 2500 on first X-axis carriage assembly 2301 of fig. 1C). Also, a batch replenishment system substantially outside the gas enclosure can be more easily used for services such as replenishing ink and solvent supplies, and changing lines carrying various inks and solvents.

FIG. 17 is a schematic view of a partial ink delivery system including a printhead ink delivery system according to the present teachings. For various embodiments of the local ink delivery system of the present teachings, the pneumatic control assembly IA may provide control between the main distribution reservoir IC and various pneumatic control sources (such as gas and vacuum sources). According to various embodiments of the local ink delivery system of the present teachings, the local ink delivery line IB may be capable of providing fluid distribution and control between the primary distribution reservoir IC and the local batch ink reservoir ID. The main distribution memory IC may be in flow communication with the plurality of printheads IE through an input manifold line IF. In the schematic diagram of fig. 17, three printheads are indicated for each of the 3 printhead device assemblies. Printhead assembly input manifold line IF may be in flow communication with printhead assembly input manifold IG. Printhead assembly input manifold IG may be in flow communication with each of a plurality of printhead devices, where each printhead device may have at least three printheads, numbered sequentially in fig. 17 as printhead 1 through printhead 9. Manifold valve IG can be integrated by using a print head assembly _V1 、IG _V2 And IG _V3 To controlFlow communication between printhead assembly input manifold IG and the respective printhead devices is established. Finally, multiple printhead assemblies may be in flow communication with a printhead assembly output waste line that is part of printhead output manifold IH. The printhead assembly output waste line can be in flow communication with a local ink waste assembly, which in turn is in flow communication with a batch ink delivery system waste assembly (see, e.g., fig. 14 and 15). Manifold line valve IH can be formed by using a print head assembly _V1 、IH _V2 And IH _V3 To control flow communication between printhead assembly output manifold IH and the various printhead devices.

Fig. 18A is a bottom expanded perspective view of a printhead assembly 2500 mounted on a printhead assembly positioning system, such as a first X-axis carriage assembly 2301 (see also fig. 1C). The first X-axis carriage assembly 2301 can be positioned on the printing system bridge 2130 in an X-axis direction relative to a substrate (such as substrate 2050 of fig. 1C). As shown in fig. 18A, the service bundle housing 2410 is mounted to the printing system bridge 2130. The service bundle housing 2410 may contain various service bundles operatively connected to the gas enclosure system including the printing system from various devices and systems. Various embodiments of service bundles may include bundled optical cables, wires, and conduits, among others, for providing optical, electrical, mechanical, and fluidic functions to various components and systems disposed within the interior of the gas enclosure system. During various processing steps, such as printing and maintenance steps, as the X-axis carriage assembly 2301 moves the printhead assembly 2500 across the printing system bridge 2130, the various service beams move accordingly. As a result, the liquid ink lines in such service bundles are subject to continued flexing and wear. In accordance with the systems and methods of the present teachings, a bulk ink delivery system external to the gas enclosure system may be in fluid communication with a local ink delivery supply system internal to the gas enclosure system, which obviates the need to run ink lines through a service bundle located in the service bundle housing 2410. Also, a batch replenishment system substantially outside the gas enclosure may be more readily used for servicing, such as replenishing ink and solvent supplies, as well as servicing or replacing various lines and valves.

As depicted in fig. 18A, printhead assembly 2500 can have a printhead assembly enclosure 2503, which printhead assembly enclosure 2503 can enclose a plurality of

printhead devices

2505A, 2505B, and 2505C mounted therein. For various embodiments of printing system 2000 of fig. 1C or printing system 2000A of fig. 13 and 16, the printhead arrangement assembly may include between about 1 and about 60 printhead arrangements, where each printhead arrangement may have between about 1 and about 30 printheads in each printhead arrangement. As depicted in fig. 18A, in accordance with the systems and methods of the present teachings, the printhead assembly 2500 can have three printhead devices, wherein each printhead device can have three printheads (see also fig. 17). As will be discussed in greater detail herein, the printhead assembly 2500 may be positioned above a maintenance system for ready placement or replacement of the printhead assembly or printheads, given the number of printhead assemblies and printheads that require constant maintenance.

As shown in the bottom perspective view of fig. 18B, printhead assembly 2500 can have

printhead devices

2505A, 2505B, and 2505C mounted by using kinematic mounts, similar to that described for the kinematic mounting of printhead assembly 2500 of fig. 13, for example. In this regard, as will be discussed in more detail later herein, various embodiments of motion mount assemblies, e.g., navicular ball and V-block assemblies, for vertically mounting embodiments of printhead devices (such as

printhead devices

2505A, 2505B, and 2505C of fig. 18B) into a printhead device assembly (such as printhead assembly 2500 of fig. 18B) may be utilized. In fig. 18B, a boat ball 1118A is depicted for each of

printhead arrangements

2505A, 2505B, and 2505C of fig. 18B.

Additionally, a camera assembly 2551 is shown mounted within the printhead assembly enclosure 2503. For various embodiments of the systems and methods of the present teachings, multiple cameras may be mounted on various devices, apparatuses, and assemblies to provide real-time visualization of operations within a gas enclosure system (such as gas enclosure system 500A of fig. 13). For example, the camera assembly 2550 of FIG. 13 and the camera assembly 2551 of FIG. 18B may be utilized, such as but not limited to, navigation and inspection. Various embodiments of a printing system camera assembly may have different specifications regarding field of view and resolution. For example, one camera may be a line scan camera for in situ particle inspection, while a second camera may be used for conventional navigation of the substrate in the gas enclosure system, or for the position of the printhead device assembly relative to the substrate. Such a camera useful for conventional navigation may be a region scan camera having a field of view in the range of about 5.4mm X4 mm at a magnification of about 0.9X to about 10.6mm X8 mm at a magnification of about 0.45X. In another example, one camera may be a line scan camera for in situ particle inspection, while a second camera may be used for precise navigation of the substrate in the gas enclosure system, e.g., for substrate alignment, or for precise position of the printhead device assembly relative to the substrate. Such a camera, which may be useful for accurate navigation, may be a region scan camera having a field of view of about 0.7mm X0.5 mm at a magnification of about 7.2X.

Fig. 19A and 19B depict various perspective views of a printhead device 2505 according to various embodiments of printhead devices of the present teachings. As previously described herein, the kinematic mounting of the printhead unit to the printing system may provide repeatable, strain-free positioning for various embodiments of the printhead unit and printhead apparatus of the present teachings. For example, the kinematic mount assembly described for the kinematic mount of printhead assembly 2500 may utilize point contact kinematic assemblies, such as ball and V-block kinematic mount assemblies. Various embodiments for a motion mounting assembly that vertically mounts multiple printhead devices into a printhead device assembly may utilize line contact motion assemblies such as, but not limited to, navigatable balls and V-block motion mounting assemblies. Various embodiments of the line contact kinematic mount assemblies may carry substantially greater loads, e.g., at least 100 times greater loads, than equivalent kinematic mount assemblies that provide point contact. Various embodiments of the kinematic mounting assembly provide significant stability for repeatable, strain-free positioning of the printhead device vertically into the printhead device assembly, as well as stability during X-axis motion of the printhead device assembly by naturally resisting motion in the X-axis direction.

In the top perspective view of fig. 19A and the bottom perspective view of fig. 19B, a first navicular ball mounting fixture 1116A of a first navicular ball 1118A and a second navicular ball mounting fixture 1116B of a second navicular ball 1118B may be seen. Third boat mounting fixture 1116C is evident in fig. 19A and 19B, and a third boat may be mounted on the back of printhead arrangement 2505. The position of a set of

navicular balls

1118A, 1118B, and 1118C, once engaged in the mating surfaces of the V-block mount, may be used for repeatable and strain-free vertical bottom insertion of printhead device 2505 into a printhead device assembly (such as printhead assembly 2500 of fig. 18A and 18B). As shown in fig. 19B, each printhead device can have 3 end-user selected

printhead assemblies

200A, 200B, and 200C. Printhead apparatus 2505 may have a first quick coupling connector 1110A that provides ease of connecting fluid lines into printhead apparatus 2505, and a second quick coupling connector 1110B that provides ease of connecting fluid lines out of printhead apparatus 2505. As schematically illustrated by the fluidic system for various embodiments of the local ink delivery system in FIG. 17, flow communication of the local ink delivery system for each printhead device in the printhead device assembly may be accomplished through the use of a printhead assembly manifold valve IG _V1 、IG _V2 And IG _V3 To control. As also shown in FIG. 17, flow communication from individual printhead devices in a printhead device assembly to a printhead output manifold may be accomplished through the use of a printhead assembly manifold valve IH _V1 、IH _V2 And IH _V3 To control, the printhead assembly manifold valve IH _V1 、IH _V2 And IH _V3 May be part of the printhead output manifold IH of fig. 17. Various embodiments of a printhead output manifold may be in flow communication with a local ink waste assembly (such as, for example, local ink waste assembly 3800 of fig. 16). In FIGS. 19A and 19B, an input printhead assembly manifold valve IG is shown for printhead device 2505 _V And output printhead assembly manifold valve IH _V 。

Fig. 19C depicts a printhead device motion mounting plate 1340 having a first, second, and third V-

block

1348A, 1348B, 1348C that are the mating surfaces of the first, second, and

third navicular balls

1118A, 1118B, 1118C of fig. 19A and 19B, respectively. A first V-block 1348A, a second V-block 1348B, and a third V-block 1348C may be secured to the printhead device motion mounting plate 1340 using a first V-block mounting fixture 1342A, a second V-block mounting fixture 1342B, and a third V-block mounting fixture 1342C, respectively. As depicted in fig. 19A-19C, a first V-block 1348A is a mating surface of the first navicular 1118A, a second V-block 1348B is a mating surface of the second navicular 1118B, and a third V-block 1348C is a mating surface of the third navicular 1118C. Fig. 19D depicts a printhead device unit 1300 in which a printhead device 2505 is mounted on a printhead device motion mounting plate 1340 using a boat ball and V-block motion mount. For example, in fig. 19D, a first navicular 1118A as shown in fig. 19B is mounted to a first navicular mount fixture 1116A and engaged in a first V-block 1348A, the first V-block 1348A being mounted on a first V-block mount fixture 1342A. As previously described herein, the first V-block mounting fixture 1342A is one of three V-block mounting fixtures mounted to the printhead device motion mounting plate 1340. In this regard, the coupling of the first navicular balls 1118A to the first V-block 1348A for the printhead device unit 1300 of fig. 19D is an example of the second and

third navicular balls

1118B and 1118C being coupled to the second and third V-

blocks

1348B and 1348C, respectively. In addition to the printhead device motion mounting plate 1340, various embodiments of mounting assemblies for a printhead device unit (such as the printhead device unit 1300 of fig. 19D) can include a printhead device front mounting plate 1341 and first and second printhead

side mounting plates

1343A, 1343B. Each of the quick-coupling connectors as shown in fig. 19A and 19B may be mounted to the printhead device-side mounting plate as depicted in fig. 19D for the first quick-coupling connector 1110A mounted to the first printhead device-side mounting plate 1343A.

In accordance with various systems and methods of the present teachings, a printhead device (such as

printhead devices

2505A, 2505B, and 2505C of fig. 18A and 18B) can be inserted manually or automatically from the bottom of printhead assembly 2500. For example, as depicted in fig. 1D, print head installation or replacement may be performed with a robot. As previously discussed herein with reference to fig. 13, a gas enclosure (such as gas enclosure 1000A) may have an auxiliary panel assembly 1330 that may enclose a printhead management system 2701. In fig. 1D, the installation and replacement of the print head device or print head can be performed in the auxiliary panel assembly 1330 by using a robot 2530. The printhead replacement module 2713 of the printhead management system 2701 of fig. 1D may include a docking station for a printhead device having at least one printhead, and storage containers for multiple printhead devices and multiple printheads. Each printhead assembly of the present teachings can include between about 1 and about 60 printhead devices, and each printhead device can have between about 1 and about 30 printheads (see, for example and without limitation, printhead assembly 2500 of fig. 1D and 18A). Thus, in addition to having between about 1 and about 60 print head devices, various embodiments of a printing system of the present teachings can have between about 1 and about 1800 print heads. As previously discussed herein, a printhead device (such as printhead device 2505 of fig. 19A and 19B) may be installed or replaced by strain free bottom insertion of a printhead device in a printhead assembly (such as printhead assembly 2500 of fig. 18B), a bottom view of which is indicated in fig. 1D.

Fig. 20 is a schematic diagram illustrating a gas enclosure system 500B. Various embodiments of a gas enclosure system 500B according to the present teachings can include a gas enclosure assembly 1000B for housing a printing system, a gas purge loop 3130 in flow communication with gas enclosure assembly 1000B, and at least one thermal regulation system 3140. Additionally, various embodiments of the gas enclosure system 500B may have a pressurized inert gas recirculation system 3000 that may supply inert gas for operating various devices, such as a substrate floatation table of an OLED printing system. As will be discussed in more detail subsequently below, various embodiments of the pressurized inert gas recirculation system 3000 may utilize compressors, blowers, and a combination of both as a source for various embodiments of the pressurized inert gas recirculation system 3000. Additionally, the gas enclosure system 500B may have a circulation and filtration system (not shown) internal to the gas enclosure system 500B.

As depicted in fig. 20, for various embodiments of gas enclosure assemblies according to the present teachings, the design of the filtration system may separate the inert gas circulating through gas purification loop 3130 from the inert gas constantly circulating and filtering inside for various embodiments of gas enclosure assemblies. Gas purification loop 3130 includes an outlet line 3131 from gas enclosure assembly 500B to solvent removal component 3132 and then to gas purification system 3134. The inert gas, purged of solvent and other reactive gas species (such as oxygen and water vapor), is then returned to gas enclosure assembly 1000B through inlet line 3133. Gas purification loop 3130 may also include suitable tubing and connections, and sensors, such as oxygen, water vapor, and solvent vapor sensors. A gas circulation unit (such as a fan, blower, or motor) may be provided separately or integrated, for example, in gas purification system 3134, to circulate gas through gas purification loop 3130. According to various embodiments of the gas enclosure assembly, although solvent removal system 3132 and gas purification system 3134 are shown as separate units in the schematic shown in fig. 20, solvent removal system 3132 and gas purification system 3134 may be housed together as a single purification unit.

Gas purification loop 3130 of fig. 20 may have solvent removal system 3132 placed upstream of gas enclosure purification system 3134, such that inert gas circulating from gas enclosure assembly 100B passes through solvent removal system 3132 via outlet line 3131. According to various embodiments, solvent removal system 3132 may be a solvent capture system based on absorbing solvent vapors from an inert gas passing through solvent removal system 3132 of fig. 20. One or more beds of adsorbents (e.g., without limitation, activated carbon, molecular sieves, etc.) can effectively remove various organic solvent vapors. For various embodiments of gas enclosure systems, cold trap techniques may be employed to remove solvent vapors in solvent removal system 3132. As previously discussed herein, for various embodiments of gas enclosure systems according to the present teachings, sensors (such as oxygen, water vapor, and solvent vapor sensors) may be used to monitor the effective removal of such species from inert gas that is continuously circulated through the gas enclosure system (such as gas enclosure system 500B of fig. 20). Various embodiments of the solvent removal system may indicate when the adsorbent (such as activated carbon, molecular sieve, etc.) has reached capacity so that one or more beds of adsorbent may be regenerated or replaced. Regeneration of the molecular sieve may involve heating the molecular sieve, contacting the molecular sieve with a forming gas, combinations thereof, and the like. Molecular sieves configured to trap various species, including oxygen, water vapor, and solvents, can be regenerated by heating and exposing to a forming gas comprising hydrogen (e.g., a forming gas comprising about 96% nitrogen and 4% hydrogen, where the percentages are by volume or by weight). Physical regeneration of activated carbon can be performed by using a similar process of heating under an inert environment.

Any suitable gas purification system can be used for gas purification system 3134 of gas purification loop 3130 of fig. 20. Gas purification systems commercially available from MBRAUN Inc., of Statham, new Hampshire or Innovative Technology of Amesbury, massachusetts may be useful for integration into various embodiments of a gas enclosure assembly in accordance with the present teachings. Gas purification system 3134 may be used to purify one or more inert gases in gas enclosure system 500B, e.g., to purify the entire gas environment within the gas enclosure assembly. As previously discussed herein, gas purification system 3134 may have a gas circulation unit, such as a fan, blower, or motor, for circulating gas through gas purification loop 3130. In this regard, the gas purification system can be selected based on the volume enclosed, which can define a volumetric flow rate for moving the inert gas through the gas purification system. For having a volume of up to about 4m ³ Various embodiments of a gas enclosure system of the gas enclosure assembly of (a); can be used and can move about 84m ³ A gas purification system of/h. For having a volume of up to about 10m ³ Various embodiments of a gas enclosure system of the gas enclosure assembly of (1); can be used and can move about 155m ³ A gas purification system of/h. For a container having a volume of about 52 to 114m ³ In various embodiments of the gas enclosure assembly, more than one gas purification system may be used.

Any suitable gas filtration or purification device may be included in gas purification system 3134 of the present teachings. In some embodiments, the gas purification system may include two parallel purification devices such that one of the devices may be removed from the pipeline for maintenance, while the other device may be used to continue system operation without interruption. In some embodiments, for example, the gas purification system can include one or more molecular sieves. In some embodiments, the gas purification system may include at least a first molecular sieve and a second molecular sieve, such that, when one of the molecular sieves is saturated with impurities, or otherwise deemed to be insufficiently effective to operate, the system may switch to the other molecular sieve while regenerating the saturated or non-effective molecular sieve. A control unit may be provided to determine the operating efficiency of each molecular sieve, to switch between operation of different molecular sieves, to regenerate one or more molecular sieves, or a combination thereof. As previously discussed herein, the molecular sieve may be regenerated or recycled.

The thermal conditioning system 3140 of fig. 20 may include at least one cooler 3142 that may have a fluid outlet line 3141 for circulating coolant into the gas enclosure assembly and a fluid inlet line 3143 for returning coolant to the cooler. At least one fluid cooler 3142 may be provided to cool the gaseous environment within the gas enclosure system 500B. For various embodiments of the gas enclosure system of the present teachings, fluid cooler 3142 delivers a cooling fluid to a heat exchanger within the enclosure, wherein an inert gas is delivered over the filtration system of the enclosure interior. At least one fluid cooler may also be provided to the gas enclosure system 500B to cool heat released by equipment enclosed within the gas enclosure system 500B. For example, but not limiting of, at least one fluid cooler may also be provided to gas enclosure system 500B to cool heat generated by the OLED printing system. The thermal regulation system 3140 may include a thermal exchange or Peltier (Peltier) device and may have various cooling capabilities. For example, for various embodiments of the gas enclosure system, the cooler may provide a cooling capacity of from about 2kW to about 20 kW. Various embodiments of the gas enclosure system may have multiple fluid coolers that may cool one or more fluids. In some embodiments, the fluid cooler may utilize several fluids as the coolant, such as, but not limited to, water, antifreeze, refrigerant, and combinations thereof as the heat exchange fluid. Suitable leak-free, locking connections may be used to connect associated piping and system components.

As previously discussed herein, the present teachings disclose various embodiments of a gas enclosure system that may include a printing system enclosure defining a first volume and an auxiliary enclosure defining a second volume. Various embodiments of the gas enclosure system may have an auxiliary enclosure that may be sealingly constructed as part of the gas enclosure assembly. According to the systems and methods of the present teachings, the auxiliary enclosure may be sealably isolated from the printing system enclosure and may be open to the environment outside of the gas enclosure assembly without exposing the printing system enclosure to the outside environment. Such physical isolation for performing, for example, but not limited to, secondary enclosure of various printhead management processes can be performed to eliminate or minimize exposure of the printing system enclosure to contaminants, such as air and water vapor and various organic solvents, as well as particle contamination. Various printhead management processes, which may include measurement and maintenance processes with respect to the printhead assembly, may be performed with little or no interruption to the printing process, thereby minimizing or eliminating gas enclosure system downtime.

For a gas enclosure system having a printing system enclosure defining a first volume and an auxiliary enclosure defining a second volume, these two volumes can be easily integrated with a gas circulation, filtration, and purging assembly to form a gas enclosure system that can maintain an inert, substantially low particle environment for processes requiring such an environment with little or no interruption of the printing process. According to various systems and methods of the present teachings, the printing system enclosure may introduce a sufficiently low contamination level that the purging system may remove contamination before it can affect the printing process. Various embodiments of the secondary enclosure may be a substantially smaller volume of the overall volume of the gas enclosure assembly and may be easily integrated with gas circulation, filtration, and purging components to form a low-particle environment that may quickly recover inertness after exposure to the external environment, thereby providing a little or no interruption of the printing process.

In addition, various embodiments of the secondary enclosure may be integrated with a set of dedicated environmental conditioning system components (such as lighting, gas circulation and filtration, gas purification, and thermostatic components). In this regard, various embodiments of a gas enclosure system including a secondary enclosure that may be sealingly isolated as a section of a gas enclosure assembly may have a controlled environment set to be the same as a first volume defined by the gas enclosure assembly housing the printing system. Further, various embodiments of a gas enclosure system including an auxiliary enclosure that may be sealingly isolated as a section of a gas enclosure assembly may have a controlled environment set differently than a controlled environment of a first volume defined by the gas enclosure assembly housing the printing system.

While the above examples refer to cooling capacity and cooling applications, the above examples may also be applied to applications that include buffering of substrates in a controlled environment, or applications where the circulating gas may be maintained at a similar temperature to other parts of the system, in order to avoid unwanted heat transfer from the substrates being manufactured or to avoid disruption of temperature uniformity across or between substrates.

Fig. 21A and 21B generally illustrate examples of gas enclosure systems for integrating and controlling non-reactive gas and Clean Dry Air (CDA) sources, such as may be used to establish the controlled environment mentioned in other examples described elsewhere herein, and such as may include a supply of pressurized gas for use with a floating stage. Fig. 22A and 22B generally illustrate examples of gas enclosure systems for integrating and controlling non-reactive gas and Clean Dry Air (CDA) sources, such as may be used to establish the controlled environment mentioned in other examples described elsewhere herein, and such as may include a blower circuit to provide, for example, pressurized gas and at least a partial vacuum for use with a floating stage. Figure 22C generally illustrates another example of a system for integrating and controlling one or more sources of gas or air to create a floating control zone that includes as part of a floating conveyance system.

Various examples described herein include environmentally controlled enclosed modules. The enclosure assembly and corresponding support apparatus may be referred to as a "gas enclosure system," and such enclosure assemblies may be constructed in a contoured manner that reduces or minimizes the internal volume of the gas enclosure assembly, while providing a working volume for accommodating various areas of influence of printing system components, such as deposition (e.g., printing), holding, loading, or processing modules described herein. For example, for various examples of gas enclosure assemblies of the present teachings that encompass, for example, substrate sizes from Gen 3.5 to Gen 10, a contoured gas enclosure assembly according to the present teachings may have approximately 6m ³ To about 95m ³ The gas in between encloses a volume. Various examples of contoured gas enclosure assemblies according to the present teachings may have, for example, without limitation, about 15m ³ To about 30m ³ In between, which may be useful for, for example, but not limited to, gen 5.5 to Gen 8.5 substrate sizes or other substrate sizes. Various examples of secondary enclosures can be built as sections of a gas enclosure assembly and easily integrated with gas circulation and filtration and purification components to form a gas enclosure system that can maintain a controlled, substantially low-particle environment for processes requiring such an environment.

As shown in fig. 21A and 22A, various examples of gas enclosure systems may include a pressurized non-reactive gas recirculation system. Various examples of pressurized gas recirculation circuits may utilize compressors, blowers, and combinations thereof. In accordance with the present teachings, several engineering challenges are presented in order to provide various examples of pressurized gas recirculation systems in gas enclosure systems. First, under typical operation of a gas enclosure system without a pressurized non-reactive gas recirculation system, the gas enclosure system may be maintained at a slightly positive internal pressure (e.g., above atmospheric pressure) relative to the external pressure to prevent external gas or air from entering the interior in the event of any leak in the gas enclosure system. For example, under typical operation, for various examples of gas enclosure systems of the present teachings, the interior of the gas enclosure system may be maintained at, for example, a pressure of at least 2mbarg, for example, at a pressure of at least 4mbarg, at a pressure of at least 6mbarg, at a pressure of at least 8mbarg, or at a higher pressure, relative to the ambient environment outside the enclosure system.

Maintaining a pressurized gas recirculation system within a gas enclosure system can be challenging because it presents a dynamic and continuous balancing action with respect to maintaining a slight positive internal pressure of the gas enclosure system while continuously introducing pressurized gas into the gas enclosure system. Further, the variable requirements of the various devices and equipment may create irregular pressure profiles for the various gas enclosure assemblies and systems of the present teachings. Maintaining a dynamic pressure balance of the gas enclosure system maintained at a slight positive pressure relative to the external environment under such conditions may provide for continued manufacturing process integrity. For various examples of gas enclosure systems, a pressurized gas recirculation system according to the present teachings may include various examples of pressurized gas circuits that may utilize at least one of a compressor, an accumulator, a blower, and combinations thereof. Various examples of pressurized gas recirculation systems, including various examples of pressurized gas circuits, may have a specially designed pressure control bypass circuit that may provide the internal pressure of the non-reactive gas in the gas enclosure system of the present teachings at a stable, defined value. In various examples of the gas enclosure system, the pressurized gas recirculation system may be configured to recirculate the pressurized gas via the pressure control bypass loop when a gas pressure in an accumulator of the pressurized gas loop exceeds a preset threshold pressure. The threshold pressure can be, for example, in a range from between about 25psig to about 200psig, or, more specifically, in a range from between about 75psig to about 125psig, or, more specifically, in a range from between about 90psig to about 95 psig. In this regard, a gas enclosure system of the present teachings having a pressurized gas recirculation system with various examples of a specially designed pressure control bypass loop may maintain the balance of having a pressurized gas recirculation system in a sealed gas enclosure in accordance with the present teachings, various devices and apparatus may be disposed inside the gas enclosure system and in flow communication with various examples of the pressurized gas recirculation system. For various examples of gas enclosures and systems of the present teachings, the use of various pneumatically operated devices and apparatus may provide low particle generation performance, as well as low maintenance. Exemplary devices and apparatus that may be disposed inside a gas enclosure system and in flow communication with various pressurized gas circuits may include: such as, but not limited to, one or more pneumatic robots, substrate floatation tables, air bearings, air sleeves, compressed gas tools, pneumatic actuators, and combinations thereof. The substrate floatation table and air bearings may be used to operate various aspects of the printing system according to various examples of the gas enclosure system of the present teachings. For example, a substrate floatation table utilizing air bearing technology may be used to transport the substrate into position in the printhead chamber, as well as to support the substrate during the printing process.

For example, as shown in fig. 21A, 21B, 22A, and 22B, various examples of

gas enclosure systems

500C and 500D may have an external gas loop 3200 for integrating and controlling a non-reactive gas source 3201 and a Clean Dry Air (CDA) source 3203 used in various aspects of the operation of the

gas enclosure systems

500C and 500D. As previously described, the

gas enclosure systems

500C and 500D may also include various examples of internal particulate filtration and gas circulation systems, as well as various examples of external gas purification systems. Such examples of gas enclosure systems may include gas purification systems for purifying various reactive species from a gas. Some common non-limiting examples of non-reactive gases may include nitrogen, any noble gas, and any combination thereof. Various examples of gas purification systems according to the present teachings can maintain the levels of various species of various reactive species (including various reactive atmospheric gases such as water vapor, oxygen, ozone, and organic solvent vapor) at 1000ppm or less, for example, 100ppm or less, 10ppm or less, or 1.0ppm or less, or at 0.1ppm or less. In addition to the external loop 3200 for integrating and controlling the gas source 3201 and the CDA source 3203, the gas enclosure system 500C and the gas enclosure system 500D may have a compressor loop 3250, which compressor loop 3250 may supply gas to operate various devices and equipment that may be disposed in the interior of the gas enclosure system 500C and the gas enclosure system 500D. A vacuum system 3270 may also be provided, such as in communication with gas enclosure assembly 1005 via line 3272 when valve 3274 is in an open position.

Compressor loop 3250 of fig. 21A can include a compressor 3262, a first accumulator 3264, and a second accumulator 3268 configured in flow communication. Compressor 3262 may be configured to compress the gas extracted from gas enclosure assembly 1005 to a desired pressure. The inlet side of compressor loop 3250 may be in flow communication with gas enclosure assembly 1005 via gas enclosure assembly outlet 3252 through line 3254 having valve 3256 and check valve 3258. Compressor loop 3250 may be in flow communication with gas enclosure assembly 1005 on an outlet side of compressor loop 3250 via outer gas loop 3200. Accumulator 3264 can be disposed between compressor 3262 and the junction of compressor loop 3250 and outer gas loop 3200, and can be configured to generate a pressure of 5psig or greater. A second accumulator 3268 may be in compressor loop 3250 to provide damping fluctuations due to compressor piston cycles of approximately 60 Hz. For various examples of compressor loop 3250, first accumulator 3264 may have a capacity of between about 80 gallons and about 160 gallons, while second accumulator may have a capacity of between about 30 gallons and about 60 gallons. According to various examples of the gas enclosure system 500C, the compressor 3262 can be a zero entry compressor (zero entry compressor). Various types of zero-entry compressors may be operated without atmospheric gas leakage into various examples of the gas enclosure systems of the present teachings. Various examples of zero-entry compressors may be operated continuously, for example, during manufacture, with the use of various devices and equipment that require compressed gas.

Accumulator 3264 may be configured to receive and accumulate compressed gas from compressor 3262. The accumulator 3264 may supply compressed gas in the gas enclosure assembly 1005 as needed. For example, accumulator 3264 may provide gas to maintain pressure of various components of gas enclosure assembly 1005 (such as, but not limited to, one or more of a pneumatic robot, a substrate floatation table, an air bearing, an air bushing, a compressed gas tool, a pneumatic actuator, and combinations thereof). As shown in fig. 21A for gas enclosure system 500C, gas enclosure assembly 1005 may have a printing system 2005 enclosed therein. As schematically depicted in fig. 21A, the printing system 2005 may be supported by a printing system base 2150, which may be a granite table. The printing system base 2150 may support a substrate support device such as a chuck, for example, but not limited to, a vacuum chuck, a substrate floating chuck having a pressure port, and a substrate floating chuck having a vacuum and pressure port. In various examples of the present teachings, the substrate support apparatus can be a substrate floating stage, such as substrate floating stage 2250. The substrate floating stage 2250 may be used for frictionless support of the substrate. In addition to low particle generating float stations, the printing system 2005 may have a Y-axis motion system with an air sleeve for frictionless Y-axis transport of substrates.

Additionally, printing system 2005 may have at least one X, Z axis carriage assembly with motion control provided by a low particle generating X axis air bearing assembly. Various components of the low particle generating motion system, such as the X-axis air bearing assembly, may be used in place of, for example, various particle generating linear mechanical bearing systems. For various examples of gas enclosures and systems of the present teachings, the use of various pneumatically operated devices and apparatus may provide low particle generation performance, as well as low maintenance. Compressor loop 3250 may be configured to continuously supply pressurized gas to various devices and equipment of gas enclosure system 500C. In addition to the supply of pressurized gas, substrate float stage 2250 of printing system 2005 utilizing air bearing technology also utilizes a vacuum system 3270 that communicates with gas enclosure assembly 1005 through line 3272 when valve 3274 is in the open position.

A pressurized gas recirculation system according to the present teachings can have a pressure control bypass loop 3260 as shown in fig. 21A for compressor loop 3250, which pressure control bypass loop 3260 is used to compensate for variable demand of pressurized gas during use, thereby providing dynamic balancing of various examples of gas enclosure systems of the present teachings. For various examples of gas enclosure systems according to the present teachings, a bypass loop may maintain a constant pressure in accumulator 3264 without disrupting or changing the pressure in enclosure 1005. Bypass loop 3260 may have a first bypass inlet valve 3261 on the inlet side of the bypass loop, which first bypass inlet valve 3261 is closed unless bypass loop 3260 is used. Bypass loop 3260 may also have a back pressure regulator 3266, which may be used when second valve 3263 is closed. Bypass loop 3260 may have a second accumulator 3268 disposed at an outlet side of bypass loop 3260. For the example of compressor loop 3250 with a zero-entry compressor, bypass loop 3260 may compensate for small pressure excursions that may occur over time during use of the gas enclosure system. Bypass loop 3260 may be in flow communication with compressor loop 3250 on an inlet side of bypass loop 3260 when bypass inlet valve 3261 is in an open position. When bypass inlet valve 3261 is open, gas diverted through bypass loop 3260 can be recycled to the compressor if gas from bypass loop 3250 is not required within the interior of gas enclosure assembly 1005. Compressor loop 3250 is configured to bypass gas through bypass loop 3260 when the pressure of the gas in accumulator 3264 exceeds a preset threshold pressure. The preset threshold pressure of accumulator 3264 can be between about 25psig and about 200psig at a flow rate of at least about 1 cubic foot per minute (cfm), or between about 50psig and about 150psig at a flow rate of at least about 1 cubic foot per minute (cfm), or between about 75psig and about 125psig at a flow rate of at least about 1 cubic foot per minute (cfm), or between about 90psig and about 95psig at a flow rate of at least about 1 cubic foot per minute (cfm).

Various examples of compressor loop 3250 may utilize various compressors other than a zero-entry compressor, such as a variable speed compressor or a compressor that can be controlled to an on or off state. As previously discussed herein, the zero entry compressor ensures that atmospheric reactive species may not be introduced into the gas enclosure system. Likewise, any compressor configuration that prevents the introduction of atmospheric reactive species into the gas enclosure system may be used for compressor loop 3250. According to various examples, the compressor 3262 of the gas enclosure system 500C can be housed in, for example, but not limited to, a hermetically sealed enclosure. The housing interior may be configured to be in flow communication with a source of gas (e.g., the same gas that forms the gaseous environment for the gas enclosure assembly 1005). For various examples of compressor loop 3250, compressor 3262 can be controlled at a constant speed to maintain a constant pressure. In other examples of compressor loop 3250 that do not utilize a zero entry compressor, compressor 3262 can be turned off when a maximum threshold pressure is reached and compressor 3262 can be turned on when a minimum threshold pressure is reached.

In fig. 22A for gas enclosure system 500D, blower loop 3280 utilizing vacuum blower 3290 is shown for operation of substrate floating stage 2250 of printing system 2005, all housed in gas enclosure assembly 1005. As previously discussed herein with respect to compressor loop 3250, blower loop 3280 may be configured to continuously supply pressurized gas to substrate floating stage 2250 of printing system 2005.

Various examples of gas enclosure systems that may utilize a pressurized gas recirculation system may have various circuits that utilize various sources of pressurized gas, such as at least one of a compressor, a blower, and combinations thereof. In fig. 22A for gas enclosure system 500D, compressor loop 3250 can be in flow communication with external gas loop 3200, which external gas loop 3200 can be used for gas supply of high consumption manifold 3225 as well as low consumption manifold 3215. For various examples of gas enclosure systems according to the present teachings as shown in fig. 22A for gas enclosure system 500D, high consumption manifold 3225 may be used to supply gas to various devices and equipment, such as, but not limited to, one or more of a substrate floatation table, a pneumatic robot, an air bearing, an air bushing, and a compressed gas tool, and combinations thereof. For various embodiments of a gas enclosure system according to the present teachings, low consumption 3215 may be used to supply gas to various equipment and devices, such as, but not limited to, one or more of an isolator and a pneumatic actuator, and combinations thereof.

For the various examples of gas enclosure systems 500D of fig. 22A and 22B, blower loop 3280 may be used to supply pressurized gas to various examples of substrate floating stage 2250. In addition to the supply of pressurized gas, substrate floating station 2250 of printing system 2005 utilizing air bearing technology utilizes a vacuum blower 3290 that communicates with gas enclosure assembly 1005 through line 3292 when valve 3294 is in an open position. An outer housing 3282 of blower circuit 3280 may maintain a first blower 3284 for supplying a source of pressurized gas to substrate floating stage 2250, and a second blower 3290 that acts as a vacuum source for substrate floating stage 2250, which substrate floating stage 2250 is housed in the gas environment in gas enclosure assembly 1005. Properties that may adapt a blower for use as a source of pressurized gas or vacuum for various examples of a substrate floatation table include: for example, but not limited to, it has high reliability; making it low maintenance, with variable speed control, and with a wide range of flow volumes; can provide about 100m ³ H to about 2,500m ³ Volume flow rate between/h. Various examples of blower loop 3280 additionally can have a first isolation valve 3283 at an inlet end of blower loop 3280, and a check valve 3285 and a second isolation valve 3287 at an outlet end of blower loop 3280.Various examples of blower loop 3280 can have an adjustable valve 3286, which adjustable valve 3286 can be, for example, but not limited to, a gate valve, a butterfly valve, a needle valve, or a ball valve; and a heat exchanger 3288 for maintaining the gas at a defined temperature from blower loop 3280 to substrate floating stage 2250.

Fig. 22A depicts an external gas loop 3200 for integrating and controlling a gas source 3201 and a Clean Dry Air (CDA) source 3203 used in various aspects of the operation of the gas enclosure system 500C of fig. 21A and the gas enclosure system 500D of fig. 22A, also shown in fig. 21A. The external gas loop 3200 of fig. 21A and 22A can include at least four mechanical valves. These valves include a first mechanical valve 3202, a second mechanical valve 3204, a third mechanical valve 3206, and a fourth mechanical valve 3208. These various valves are located in positions in the various flow lines that allow for control of non-reactive gas and air sources, such as Clean Dry Air (CDA). According to the present teachings, the non-reactive gas may be any gas that does not undergo a chemical reaction under a defined set of conditions. Some common non-limiting examples of non-reactive gases may include nitrogen, any noble gas, and any combination thereof. A sheath gas line 3210 extends from the sheath gas source 3201. Housing gas line 3210 continues to extend linearly as low consumption manifold line 3212, which low consumption manifold line 3212 is in flow communication with low consumption manifold 3215. A cross-line first section 3214 extends from a first flow junction 3216 at the intersection of the house gas line 3210, the low-consumption manifold line 3212, and the cross-line first section 3214. The cross-line first section 3214 extends to a second flow junction 3218. A compressor gas line 3220 extends from accumulator 3264 of compressor loop 3250 and terminates at a second flow junction 3218. CDA line 3222 extends from CDA source 3203 and continues as a high consumption manifold line 3224, which is in flow communication with high consumption manifold 3225. A third flow junction 3226 is positioned at the intersection of the cross-line second section 3228, the clean dry air line 3222, and the high consumption manifold line 3224. A cross-line second section 3228 extends from the second flow junction 3218 to the third flow junction 3226. Various components that are high cost may be supplied CDA by way of high cost manifold 3225 during maintenance. Isolating the compressor by using

valves

3204, 3208, and 3230 can prevent reactive species (such as ozone, oxygen, and water vapor) from contaminating the gas within the compressor and accumulator.

In contrast to fig. 21A and 22A, fig. 21B and 22B show the following configuration in principle: the pressure of the gas inside the gas enclosure assembly 1005 may be maintained within a desired or specified range, such as using a valve coupled to the pressure monitor P, wherein the valve allows for venting of the gas to another enclosure, system, or area around the gas enclosure assembly 1005 using information obtained from the pressure monitor. As described in other examples herein, such gases may be recycled and reprocessed. As mentioned above, such regulation may assist in maintaining a slight positive internal pressure of the gas enclosure system, as the pressurized gas is also simultaneously introduced into the gas enclosure system. The variable requirements of the various devices and equipment may create irregular pressure distributions for the various gas enclosure assemblies and systems of the present teachings. Thus, the methods shown in fig. 21B and 22B may be used in addition to, or in place of, the other methods described herein, in order to assist in maintaining a dynamic pressure balance of the gas enclosure system maintained at a slight positive pressure relative to the environment surrounding it.

Fig. 22C generally illustrates another example of a system 500E for integrating and controlling one or more sources of gas or air to establish a floating control zone included as part of a floating conveyance system. Similar to the example of fig. 1C, 22A, and 22B, fig. 22C generally illustrates a floating stage 2250. An input region 2201 and an output region 2203 are additionally shown in the illustrative example of fig. 22C. For purposes of illustration only,

regions

2201, 2202, 2203 are referred to as input, print, and output. Such areas may be used for other process steps, such as transport of the substrate or support of the substrate, such as during one or more of holding, drying, and heat treatment of the substrate in one or more other modules. In the illustration of fig. 22C, first blower 3284A is configured to provide pressurized gas in one or more input or

output regions

2201 or 2203 of the floating stage apparatus. Such pressurized gas may be temperature controlled, such as using a first cooler 142A coupled to the first heat exchanger 1502A. A first filter 1503A may be used to filter such pressurized gas. A temperature monitor 8701A can be coupled to the first cooler 142 (or other temperature controller).

Similarly, second blower 3284B may be coupled to a print region 2202 of the floating stage. The separate chiller 142B may be coupled to a circuit that includes a second heat exchanger 1502B and a second filter 1503B. Second temperature monitor 8701B may be used to provide independent adjustment of the temperature of the pressurized gas provided by second blower 3284B. In an illustrative example, as previously described herein with respect to fig. 1C, the input and

output regions

2201 and 2203 are supplied with positive pressure, but the printing region 2202 may include the use of a combination of positive pressure and vacuum control to provide precise control of substrate position. For example, using this combination of positive pressure and vacuum control, the substrate may be controlled exclusively by using a floating gas cushion provided by the gas enclosure system 500D in the zone defined by the printing region 2202. A vacuum may be established by third blower 3290, such as also providing at least a portion of the supplemental gas for first and

second blowers

3284A or 3284B within blower housing 3282.

It should be understood that various alternatives to the embodiments of the disclosure described herein may be employed in practicing the disclosure. For example, a number of different fields (such as chemistry, biotechnology, high technology, pharmaceutical technology) may benefit from the present teachings. Printing is used to illustrate the utility of various embodiments of a gas enclosure system according to the present teachings. Various embodiments of a gas enclosure system that can house a printing system can provide features such as, but not limited to, providing a hermetic seal enclosure by a cycle of construction and deconstruction, minimization of enclosure volume, and access from the outside to the inside during processing and during maintenance. Such features of various embodiments of the gas enclosure system may have an impact on functionality such as, but not limited to, providing structural integrity during processing to maintain low levels of ease of reactive species, and rapid enclosure volume transitions during maintenance cycles to minimize down time. Likewise, the various features and specifications that provide utility of substrate printing may also provide benefits to various technology areas.

While embodiments of the present disclosure have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the disclosure. It is intended that the following claims define the scope of the disclosure and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Claims

1. A system for printing a substrate, the system for printing a substrate comprising:

a printhead assembly including at least one printhead;

a floating support apparatus for supporting a substrate; and

a motion system for positioning the substrate on the floating support device relative to the printhead assembly, the motion system comprising:

a Y-axis linear air bearing movement system, the Y-axis linear air bearing movement system comprising:

a substrate gripper assembly for gripping the substrate on the floating support apparatus, the substrate gripper assembly having a pivot and linear motor assembly for rotating the substrate in an X-Y plane of an X-Y-Z Cartesian coordinate system and movable along a Y-axis of travel; and

a gripper motion control system to control rotation of the substrate; and

an X-axis linear air bearing motion system coupled to the printhead assembly.

2. The system for printing a substrate of claim 1 wherein the gripper motion control system is configured to maintain an orientation of the substrate parallel to the Y axis of travel within +/-4300 micro radians.

3. The system for printing a substrate of claim 1, wherein the floating support device has a print zone and is configured to hold the substrate at a flying height of 30 to 50 microns in the print zone.

4. The system for printing substrates of claim 1, wherein the floating support apparatus comprises a perforated plate.

5. The system for printing a substrate of claim 1, wherein the substrate gripper assembly is positioned along a side of a floating support device.

6. The system for printing substrates of claim 1, wherein the floating support device is configured to support substrates ranging in size from generation 3.5 to generation 10.

7. The system for printing a substrate of claim 1, wherein the X-axis linear air bearing motion system comprises a Z-axis moving plate assembly that couples the X-axis linear air bearing motion system to the printhead assembly.

8. The system for printing a substrate of claim 7, wherein the Z-axis moving plate assembly includes a pneumatic balancing system to counteract a force of a load against the Z-axis moving plate assembly.

9. The system for printing a substrate of claim 1, wherein the floating support apparatus comprises a table having a print zone with pressure and vacuum control ports.

10. The system for printing a substrate of claim 1, wherein the printhead assembly, the floating support apparatus, and the motion system are disposed in a pressure controlled environment.

11. The system for printing a substrate of claim 10, wherein the pressure controlled environment is a positive pressure environment.

12. The system for printing substrates of claim 10, wherein the pressure controlled environment is provided by an enclosure housing the printhead assembly, the floating support device and the motion system, and coupled to a pressure control system.

13. The system for printing substrates of claim 12, wherein the pressure control system is a pressurized gas recirculation system.

14. The system for printing substrates of claim 13, wherein the pressurized gas recirculation system comprises a gas purging system.

15. The system for printing a substrate of claim 1, wherein the substrate gripper assembly comprises a vacuum chuck bar operable to grip a substrate with a vacuum force.

16. The system for printing substrates of claim 1, wherein the substrate gripper assembly is positioned along a side of the substrate support apparatus to grip the substrate at an edge region of the substrate.

17. The system for printing a substrate of claim 1 further comprising a bridge extending across the floating support device, the X-axis linear air bearing motion system configured to move the printhead assembly along the bridge.

18. The system for printing substrates of claim 1, wherein the gripper motion control system is configured to dynamically rotate the substrate gripper assembly about the Z-axis during movement of the substrate gripper assembly in the travel Y-axis direction.

19. The system for printing a substrate of claim 1, wherein the Y-axis linear air bearing motion system comprises:

a beam positioned along a side of the floating support apparatus and extending along a Y-axis;

a Y-axis carriage assembly coupled to the beam by a plurality of air bearings and to the substrate gripper assembly by a gripper motion control system.

20. The system for printing a substrate of claim 19 wherein the gripper motion control system comprises two independently operable linear motor assemblies and a pivot between the two linear motor assemblies.

21. The system for printing a substrate of claim 20, wherein each motor assembly is a voice coil.

22. A printing system, comprising:

a gas enclosure defining an interior; and

a printing system housed within the interior of the gas enclosure, the printing system comprising:

a printhead assembly including at least one printhead;

a substrate supporting apparatus for supporting a substrate, the substrate supporting apparatus being a floating stage; and

a motion system for positioning the substrate relative to the printhead assembly, the motion system comprising:

an X-Z axis motion system for controlling movement of the printhead assembly in an X-Z axis, the X-Z axis motion system comprising:

a carriage assembly mounted on the bridge, wherein the carriage assembly is configured with a linear air bearing movement system for controlling X-axis movement of the carriage assembly on the bridge;

a Z-axis moving plate assembly mounted on the carriage assembly, wherein the printhead assembly is mounted on a Z-axis moving plate; and

wherein the Z-axis moving plate is configured with a pneumatic balancing system to counteract a force of a load of the printhead assembly on the Z-axis moving plate assembly, an

A Y-axis linear air bearing motion system including a Y-axis beam positioned along a side of the floating stage and a substrate gripper assembly coupled to the Y-axis beam, the substrate gripper assembly having a linear motor assembly that rotates the substrate.

23. The printing system of claim 22, wherein the floating stage has a print zone and is configured to hold a substrate at a fly height of 30-50 microns above the floating stage.

24. The printing system of claim 22, wherein the printing system further comprises a gas circulation and filtration system.

25. The printing system of claim 22, wherein the printing system further comprises a gas purging system.

26. The printing system of claim 22, wherein the substrate gripper assembly is coupled to the Y-axis beam through an air bearing.

27. The printing system of claim 26, wherein the substrate gripper assembly comprises a vacuum chuck and a gripper motion control system coupled to the vacuum chuck.

28. The printing system of claim 24, wherein the gas circulation and filtration system comprises a pressure control system for controlling the pressure inside the gas enclosure.

29. A printing system, comprising:

a printhead assembly including at least one printhead;

an X-axis support for supporting the printhead assembly;

an X-axis linear air bearing motion system having a Z-axis moving plate assembly coupling the printhead assembly to the X-axis support;

a floating support for supporting a substrate;

a Y-axis support along a side of the floating support; and

a Y-axis linear air bearing motion system coupled to the Y-axis support and including a pivotable substrate gripper for moving the substrate on the floating support, the substrate gripper having a linear motor assembly for pivoting the substrate gripper.

30. The printing system of claim 29, wherein the Y-axis linear air bearing motion system further comprises a gripper motion control assembly for controlling rotation of the substrate.

31. The printing system of claim 30, wherein the substrate gripper is coupled to a pivot, and the gripper motion control assembly comprises two independently operable linear motor assemblies, the pivot being located between the two linear motor assemblies.

32. The printing system of claim 31, wherein the Y-axis support includes a beam extending along the floating support side, and the Y-axis linear air bearing motion system includes an air bearing carriage coupling the substrate holder to the beam.

33. The printing system of claim 32, wherein said X-axis linear air bearing motion system further comprises a Z-axis motor to move said Z-axis moving plate.

34. The printing system of claim 33, wherein said X-axis linear air bearing motion system further comprises a Z-axis pneumatic balance system.

35. The printing system of claim 29, further comprising an air enclosure housing the printhead assembly, the X-axis support, the X-axis linear air bearing motion system, the floating support, the Y-axis support, and the Y-axis linear air bearing motion system.

36. The printing system of claim 35, further comprising a pressure control system coupled to the gas enclosure.

37. The printing system of claim 36, further comprising a gas recirculation system coupled to the gas enclosure.

38. The printing system of claim 37, further comprising a gas filtration system coupled to the gas enclosure.

39. The printing system of claim 38, further comprising a gas purging system coupled to the gas enclosure.